smIDTH
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TABLE OF CONTENTS
I. CLINKER fORMATION AND CLINKER GRANULOMETRY ..,..,.., , ,..,., , 1
II. IMPORTANCI'; OF COOLER EFFICIENCY FOR HEAT CONSUMPTION 3
m. COOLER TYP-ES " , , .4
A, Cooler. '" , , ,.4
B. RP!'!Q' Cooler. , " , , , 9
C. First Generation Grate Cooler 10
D. Generation Grate Cooler , , 11
1, Pundamcntal Design Features of Second Generation (Air-Beam)
Orate Coolers " , 12
([I) Bridging (Dead) Grates and Evolved
Grate-Line Configurations . 13
(b) Alternative Grate-Line Suspensions , , 14
(c) External Spillage Conveyosr & Valves ..,,, 16
(0 Reduced F[l1I Through Grates 17
(e) Hydraulic; Drives .. . 18
(jj Clinker Crushers , 19
(g) Three-Component Control System 20
(h) Air Beam Technology , 22
(i) Elevated Resistance Grate Plates .., 23
0) Stationary Inlet Section.... . 27
2, Process Considerations ".', , 28
3, Efficiency, Recuperation and Cooler Heat Loss , 30
4, Impact of Second Generation Grate Coolers
(Air-Beam & Elevated Resistance Grate Plate Designs) .35
5, Second Generation Grate Cooler Summary and
Commentary '.'..... ,.. ,., ,.39
E. Third Grate Coolers. , .., .41
I. fundamental Design features of Third Generation Grate
Coolers "'.""""" .42
(a) Modular Design. , . 42
(b) Fixed Grate-Line For Air Distribution ..43
(c) Separate Clinker Conveying System .. 44
(d) Air Distribution Plates With Mechanical
Flow Regulators, ,.... . .45
2, Further Improvements/Developments of Third Generation Grate Coolers .48
3, Third Generation Grate Cooler Performance 51
IV, COMPARlSON OF FIRST, SECOND and THIRD GENERATION COOLER PERFORMANCE 52
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I. CLINKER FORMATION AND CLINKER GRANULOMETRY
It is a well-known fact that the granularity of clinker products can vary considerably from
one cement plant to another. Even kilns within the same plant are often found to produce
quite different clinker, although fed with the same raw mix.
FIGURE 1 shows some sieve test results obtained from a wide range of clinker samples. It
appears that the dust content, for example grains finer than half a 111m, can vary between I
and 70%. Also the presence of even a small proportion of oversize clinker, say bigger than
40mm (1-1/2"), contributes very much to the overall appearance of a clinker product.
Furthermore, clinker made up of compactly fused and well shaped nodules appears to be
completely different from clinker with a similar sieve curve, but consisting of cokelike and
sharp edged agglomerations of dust particles.
Such observations have naturally led to investigations of the factors affecting clinker
formation.
In preheater kilns, the formation of nodule shaped clinker must take place in or just above
the burning zone, since the raw mix somewhere further up in the kiln is in the form of meal.
In a wet-process kiln strong nodules often come out from the chains as determined during the
drying of slurry. The extent to which these nodules affect the final clinker granulometry, if
at all, is unknown. However, wet kilns tend to produce a coarser clinker size distribution
than do precalciner kilns.
Clinker formation is related to raw mix composition and operating conditions. The clinker
formation may start already in the calcining zone, where a certain agglomeration of the fine,
solid particles may take place aided perhaps by the presence of low melting alkali salts.
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However, the final result depends on what happens in the burning zone. Here the formation
of liquid phase begins at a temperature slightly below l300C, and the quantity of liquid
increases with the temperature up to a certain final value as shown in FIGURE 2.
The amount of liquid does not increase gradually with the temperature, but in steps on
reaching certain temperatures. Only by applying extreme temperatures can this final amount
of liquid be further increased which, however, usually has disastrous effects on coating and
lining.
The quantity of liquid phase at normal burning temperature amounts to 20-25% of the
clinker, depending on the content of alumina, iron, magnesia, and alkalies. If the quantity of
liquid phase is too small, good clinker formation will not take place. Conditions may then
be improved by changing the raw mix composition, which in practice is usually done by
adding iron ore, thus reducing the silica ratio.
In some cases it will be possible to improve the clinker formation by burning harder, even
harder than required for bringing down free lime. The reason, of course, being an increase in
liquid phase. But it is often seen that if the burning temperature is raised even further, the
result will be dusty clinker, probably due to a too low viscosity of the liquid. At several
plants we have also found a rather sharp limit to the lime saturation factor, if good clinker
grading is to be obtained; if this limit is exceeded the clinker becomes dusty.
The clinker granulometry is important for the satisfactory operation ofany cooler: There
must not be too much dust. Less than J5% minus 0.5 mm (0.02") is good. Too much clinker
plus 25 mm (I") increases the clinker temperature after the cooler because of the slow
cooling of this fraction. Less than I0% plus 25 mm (I") is good.
The clinker dust in the cooler tends to blow back into the kiln, thus establishing a dust
circulation between kiln and cooler. The dust can disturb the radiation from the flame in the
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kiln, and often it spoils the clinker formation so that the dust circulation tends toaccelerate.
Dust circulation means that the amount ofheat contained in the clinker entering the cooler
increases. This result is always to lower the efficiency of the cooler.
II. IMPORTANCE OF THE COOLER EFFICIENCY FOR THE HEAT
CONSUMPTION
A characteristic heat balance for a kiln with a 4-stage preheater and a conventional grate
cooler can look like this: (Ref. Temperature 18C - MOF)
kcal/kg MBtu/t
Heat in Exit Gas + Dust 177 .637
Surface Loss Kiln 56 .202
Surface Loss Preheater 24 .086
Cooler Loss 142 .511
Heat of Reaction 417 1.50 I
816 2.937
Total Heat Consumption 790 2.843
Ifwe look at the possibilities of bringing down the heat consumption, then about 25 kcal/kg
(0.09 MBTU/ST) can be saved in the exit gas by adding a 5th cyclone stage to the preheater,
but in some plants the full amount ofheat in the exit gas is used for drying the coal and raw
materials, so this heat is not wasted.
The surface loss from the kiln shell can be brought down by using a type of insulating bricks
in part of the kiln, but these bricks have generally a poor lifetime.
A better insulation in the preheater will partly result in a higher exit gas temperature instead
of saved heat input to the system.
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Regarding the cooler, it is so that if we could establish a perfect counterflow in the heat
exchange between clinker and air, then nearly all the heat in the clinker could be transferred
to the combustion air. Therefore, the largest potential for bringing down the heat
consumption rests with the cooler.
III. COOLER TYPES
In the following the four (4) types of coolers, considered by the industry for modern cement
kilns, are discussed. These are: planetary coolers, rotary coolers, grate coolers (both
conventional and air-beam types), and cross-bar coolers.
A. Planetary Coolers
The planetary cooler served the cement industry for many years and was originally
designed for wet process kilns with a high amount of secondary air available for the
cooler.
In modern dry process kilns with a low heat consumption, the amount of secondary
air available for cooling (when this is done with secondary air only) is only about I
kg air per kg clinker (1 lb. air per lb. clinker) or even less. This requires a very
efficient heat transfer between air and clinker obtained by cascading the clinker
through the air flow. It also requires that the internal parts in the hot end can stand
high temperatures, which is obtained with wear resisting ceramic materials.
In a planetary cooler, such as the Unax, the principle of having a number of cooler
tubes rotating with the kiln and connected directly to the kiln is used.
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A breakthrough for the new planetary cooling principles came when a kiln support
below the cooler was introduced. This permitted heavy cooler tubes with the
necessary internal fittings to be supported without excessive stresses in the kiln shel1
and opened the way for designing Unax coolers for kilns with a high capacity. The
one shown in FIGURE3 is producing 4000 tid clinker (4,400 STPD), and the cooler
consists of 10 tubes, each 2.4 x 29 m (7'IO"x 94'9"). It is only for kilns having
capacity less than 1000 tid (1100 STPD) for which it is economical to leave out the
support below.
Each cooler tube is attached to the kiln with a fixed and a movable support, welded
to heavy kiln sections as shown in FIGURE 4.
The inlet to the cooler has a special design which prevents clinker from fal1ingback
into the kiln when a tube is in top position.
The cooling is based upon cascading the clinker through the air flow. This is not as
simple as it seems, as fine clinker falling down from the lifters through the air is
carried the wrong way by the air, and an excessive number of lifters has proved to
lead to overfilling the coolers, back spilling into the kiln and high exit clinker
temperatures.
The shape and number of the lifters in the various temperature zones have to be
carefully determined by means of a mathematical model, the input being an
anticipated grading of the clinker as shown in FIGURE 5.
At the cooler outlet the fine clinker falls through a grizzly to the clinker transport,
while coarse clinker and lumps are discharged at the side to a hammer mill clinker
crusher as shown in FIGURE 6.
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In principle, coarse clinker requires more cascading and fine clinker less in the hot
end of the cooler in order to avoid excessive circulation between cooler and kiln,
which conveys more heat to the coolers. The inlet part with a special shape is lined
with castables. In recent years special, dense castables have been developed for such
a purpose, fulfilling all requirements regarding abrasion resistance, shock resistance,
chemical resistance against alkali attack etc., and the practical experience with these
modem castables has been very good.
In the cylindrical part ofthe coolers there is first a section of corrugated brick lining,
followed by cast heat resistant steel lifters of special design, either lined with steel
plates, as shown, or for the hot part with a ceramic lining, either bricks or castables.
In the cold end of the coolers, mild steel lifters with a high lifting capacity,
increasing towards the outlet, are used, and no lining is used here.
The outlet of the kiln to the coolers was previously made with steel casings, which
caused problems when exposed to high temperatures. The problems have been
solved by using a ceramic outlet made of the high quality, dense castables now
available.
The cooling effect depends, of course, on the size of the cooler. It can be expressed
as the clinker production in relation to surface and volume for the cooler tube by the
following formula:
r =Specific Load =(n P J-[_t_]or[ shT ]
* D
I 5
* L - m
25d
m
2 5d
,
Illsrna R:T fHI
UIN511'''O'1r lUJ "lrIE
Where:
p
n
L
D
clinker production in t/24 h (shT/24 h)
number of cooler tubes
length of cooler tubes in rn
cooler tube diameter in m
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A normal specific load would be 3.65 tlm
25
* d or (0.208 shT/m
2 5
) . A normal
clinker exit temperature would be 160C (320F) above ambient at this loading and
at a specific heat consumption of 780 kcal/kg for the kiln system. For calculating
expected clinker temperatures at other clinker capacities, the following relation may
be used:
Expected Clinker Tempature above ambient = 160"C * (...l)1.6 * 780kcallkg
3.6 X
Where X is the specific fuel consumption (kcal/kg) at the new conditions and y is the
cooler loading in tlm
2
.
5
* d at the new conditions.
The air velocity in the cooler tubes should not be too high to avoid excessive dust
circulation. Therefore the expression:
p
* II 0
2
n -x
4
should not exceed 70 t/m
2
or (77 shT/m
2
) .
The temperature of the clinker from a Unax cooler of an economical dry process kiln
will usually average 160C (320F) above ambient temperature. It can vary with the
clinker grading, and, of course,it increases by forced output. The temperature can be
reduced, if required, by addition of water to the coolers ncar the outlet. The
equipment required is very simple: Just a gutter around the coolers, from which the
water runs into the individual cooler tubes. The amount of water is controlled by the
315
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clinker temperature, and it has been established that I % water on clinker basis
reduces the clinker temperature by about 15-20C (68F), which is close to the
theoretical maximum. The effect on the heat consumption is therefore small, as long
as the amount of water is kept below 3% of the clinker weight.
The heat losses from a planetary cooler consist of: (I) radiation loss and (2) sensible
heat in the clinker leaving the cooler. A normal cooler loss would be: (20C ref.
temp./68F).
TYPICAL COOLER LOSS-PLANETARY TYPE
Radiation 90 kcal/kg 0.349 MBTU/shT
Clinker (150C/300on 25 kcal/kg 0.090 MBTU/shT
SUM 122 kcal/kg 0.439 MBTU/shT
This compares favorably with a conventional grate cooler especially when the
lower power consumption is also taken into consideration.
Depending on the cost relation between fuel and power, I kWh/t will often
correspond to the cost of 7 kcal/kg clinker (0.025 MBTU/shT).
It would, of course, be possible to insulate the cooler much better, but that would
lead to an excessive clinker temperature - a certain amount of heat has to be wasted
through radiation. The length of the different types of lining has to be chosen so that
the cooler shell temperature does not become excessive at any point.
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Another favorable feature is the low power consumption, only about 1.0-1.5 kWhJt
(0.9-1.5 kWhJshT) clinker added to the kiln drive and exhaust fan.
The Planetary cooler is unique in its simplicity, no excess air to handle, no motors or
fans, no instruments. In operation there is nothing to control, it is self-adjusting. One
disadvantage is that the clinker temperature is higher than for grate coolers. The
primary disadvantage is that the planetary cooler does not permit take-out for hot
tertiary air as required for modem calciner kilns. The higher noise level can also be a
problem in some areas.
B. Rotary Cooler
As mentioned above, the main drawback of the planetary cooler is that it was not
suited for modem precalciner kilns with external tertiary duct. This had (prior to the
dominance of grate coolers) given the separate rotary cooler a come-back.
The rotary cooler is also operated without excess air, but it permits take out of
tertiary air for a precalciner through a specially designed "rabbit-ear" kiln hood.
The cooler shown in FIGURE 7 is designed for a 2000 tid (2200 shT/D) kiln with
precalciner and has the dimensions 4.75 x 55 m (15'6" x 180'), which means that it is
bigger than the kiln.
Just as for the planetary cooler, the cooling is based upon cascading the clinker but
with specially designed lifters, which prevent clinker from hammering on the lining
when dropping into the large diameter cooler. The mild steel section is divided into
six compartments so that efficient cascading is permitted.
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The rotary cooler necessitates two efficient seals. The cooler has a 4.5% inclination
and a maximum rotating speed of 4.0 RPM. The power consumption for the cooler
drive is 3.5 kWh/t (3.2 kWh/shT).
Because the specific surface is lower than for a planetary cooler, the surface heat
losses are also lower, and that gives a favorable thermal efficiency, but it also results
in a higher clinker temperature, 200-250C (390-480F). Again, however, this can be
reduced somewhat by spraying water into the outlet.
The investments for a rotary cooler are higher than for a planetary cooler, but may in
some cases be lower than for a grate cooler when efficient cleaning of excess air is
required.
C. First Generation Grate Coolers
The grate cooler, however, is overwhelmingly accepted as the preferred method of
clinker cooling for today's modern cement plants.
As shown in FIGURE 8, for the traditional grate cooler, the clinker drops from the
kiln onto reciprocating, air-quenching grates with compartmentized high-pressure
cooling fans.
Below the grates, the cooler is divided into a number of compartments, each
provided with fans having adjustable inlet vanes for automatic air flow control and
minimum power consumption. Clinker spillage through the grates is collected in
hoppers and removed through air-tight flap valves to the clinker conveyor.
FIGURE 9 presents the advantages of the grate cooler over other types of coolers.
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/
.--------------------------------- -----------------------
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As shown, the reasons for grate cooler's preference are because the grate cooler is
capable of handling large outputs (10,000 MTPD or more) and because it is capable
of cooling clinker to very low temperatures (65C above ambient or less). The grate
cooler as shown in FIGURE 10 also permits recuperation of hot tertiary air for
today's precalciner kiln systems.
D. Second Generation Grate Coolers
The second generation (air-beam type) grate cooler has a standard cooler heat loss of
90 to 110 kcal/kg, which is a significant improvement over other cooler types such as
the rotary and planetary coolers. This, in itself, is remarkable since these other
cooler types operate without excess air; excess air being far and away the most
significant area of heat loss from the grate cooler.
Nevertheless, 90 to 110 kcal/kg (air-beam grate cooler heat loss) is still a substantial
portion of the overall loss of the kiln system. Therefore, the clinker cooler offers the
largest potential for further decreasing the heat consumption of modern
pyroprocessing systems as shown in FIGURE J]. Undoubtedly, further
developments will be made in the area of clinker cooling. One point is obvious: the
second generation (air-beam type) grate cooler represents a compromise between
reliability and efficiency. For this reason, third generation designs such as
F.L.Smidth's Cross-Bar Cooler or Polysius's Poly-Track Cooler or Claudius Peters
Eta Cooler or KHD's Pyrotloor Cooler have emerged in recent years.
During the period of time since Fuller Company/F.L.Smidth first developed the air-
quenching grate cooler during the late 1930s, the grate cooler emerged as the logical
choice for any new clinker cooler installation. Second generation grate cooler
designs employ a number offundamental design features that evolved over 60 years.
By the early 1990's, all of the major cement equipment suppliers were offering
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cooler designs that incorporated the latest developments in grate plate and air
distribution technologies. These "air-beam" technologies were integrated with the
fundamental design attributes which made the Grate Cooler an industry standard for
many decades.
The following section will highlight the mechanical design features present in all
second generation (air-beam) grate coolers and describe the maintenance and process
benefits of each.
1. Fundamental Design Features of Second Generation (Air-Beam) Grate
Coolers
Over the first 60 years since the introduction ofthe grate cooler, a number of
developments helped to make the grate cooler a reliable and efficient piece of
machinery; namely,
(a) Bridging (Dead) Grates and Evolved Grate-Line Configurations
(b) Grate-Line Suspension Systems (e.g. Internal Wheels)
(c) External Spillage Conveyors & Spillage Valves
(d) Reduced Fall Through Grates
(e) Hydraulic Grate Drives
(f) Clinker Crushers
(g) Three-Component Control System
(h) Air Beam Technology
(i) Elevated Resistance Grate Plates
(j) Stationary Inlet Section
Until the late 1990's the design features listed above had been the universally
accepted staples of the modern grate cooler. Though variations in design
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DNSTDTUTE
existed, all major equipment suppliers generally were offering the above
components. Moreover, the variations offered usually had very similar
results in actual practice. Adescription of maintenance and process benefits
of each component follows.
(a) Bridging (Dead) Grates and Evolved Grate-Line Configurations
. Bridging plates (dead grates) are the conversion of a moving plate to a fixed
plate by bridging from fixed row to fixed row over a moveable row. Fuller
Company/F.L.Smidth first installed bridging plates (dead grates) during the
mid-1960s in order to rectify problems associated with hot fines coming into
contact with side castings. Bridging plates (dead grates) as shown in
FIGURE 12A were installed adjacent to the side castings, then covered with
castable refractory to protect the cooler's structural frame from the hot clinker
fines. Bridging plates (dead grates) were found to improve cooler
performance and increase capacity. Observation showed reduction in cooler
width gave a deeper bed depth and greater uniformity across the width of the
cooler.
With a deeper and more uniform clinker bed, it was found that the material
cooled quicker, the air to the kiln was warmer, and the operation of the kiln-
cooler was more stable. At the time of their development, dead grates
allowed for an increase in the cooler's specific loading from 38 to 42
MTPD/m
2
. Today dead grates also are used on modem air-beam coolers,
which have a loading of 50 MTPD/m
2
or more. For these coolers, dead
grates and tapered refractory are installed on the static inlet rows as a means
to distribute clinker evenly across the cooler's width.
1) Maintenance Benefit - Bridging plates (dead grates) act as a barrier
321
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mID.TII
to prevent damage to the structural frame.
2) Process Benefit - The bridging plates allow deep bed operation,
improving cooling efficiency.
Over the years, many different grate line configurations have been employed.
The earliest grate designs were known as inclined coolers and were sloped at
10 degrees using horizontal grate plates. In order to re-gain control over the
clinker transport efficiency, grate lines of 5 degrees, 3 degrees, and
eventually 0 degrees (horizontal) were employed. The reciprocating action
V) lIll
r2'L
.:
. ,
LJ
V I.
I
P
/ V
If V
,0;/
Ifl
<:,0
;;:?:
./ Y.0 /
/
v /
Z
1/
',r
j
./
cl/
l(
A
V
V
:
,:.. .
./'
V
0,1
0,09' 0,5 ',0
5 10 50
Screen (mm)
FIGURE 1
361
362
~ ~ )
. ~
CIl
til
C'J
.r:. .
Q. 20
-::J
::J
tr
~
11l
IMPACT OF BURNING CONDITIONS ON
CLINKER FORMA TION
i
Ca, Si J:
(
~ r
I
I
Fe, Mg, AI,
. "
I 11--..
I
I
I
)
K, Na, GI, S<,
I I
~
.
Material Temperature ("C)
-
~ 35- e
-
U
0
:::>
to
v
-r-'
30
l':I
llJ
(/)
':'J
.::::
Q.
25
-0
~
1:7
-J
20
'5
2
FIGURE 2
4
Silica Ralio, Ms
363
364
PLANETARY COOLER WITH4-STAGE PREHEATER
FIGURE 3
PLANETARY COOLER
TUBE DESIGN
c-: I
!!I k/
'I.... ;":'1 I I"',':;
'\If
"\J f II j hr.=<
. ,
~ . ~
k7
V
-
'-7-
I""""
,.
cu = - !
c-c
FIGURE 4
365
PLANETARY COOLER
DESIGNOF INTERNALS
Il' ;
,. IJOQ
c
.- ..-
I.
i
I i I I I
_IIttH+Hi
I
,Ill II I . f 1-
-
r- ' 'I
i._ \ ',///
I ............. tr ...1:11 .... h"'.. rt
-1
.!.. ..!. .s, .s,
..!..
AI
1JZl
r!;J
ly
'L
.-
1
\ \
\ :".-::"1
',r7",
Ir'A
I'
FIGURE 5
366
. ",: v '
UNAX CLINKER COOLER
FIGURE 6
367
E-E
D-D c-c
FIGURE 7
Brick LI nlng
ROTARYKILN
8-B
Max: 6 RPM
A-A
368
First Generation AIR-QUENCHING RECIPROCATING
GRATE COOLER
FIGURE 8
369
370
GRATE COOLER
ADVANTAGES
ABILITY TO HANDLE lARGE
CAPACITIES
CAPABLE OF ACHIEViNG lOW CLINKER
TEMPERATURES
FAVORABLE HEAT
PERMITS TAKE-OUT OF HOT TERTIARY
AIR
GREATEST POTENTIAL FOR
DEVELOPMENT
FIGURE 9
Second Generation GRA TE COOLER
FIGURE 10
371
372
POTENTIAL FOR DECREASINGFUEL CONSUMPTION
TYPICAL HEAT LOSSES
(5-STAGE PREHEATER)
lOSS SAVINGS
kcallkg cl POTENTIAL
Exit Gases, incl. Dust 165 Moderate
Radiation Losses:
- Preheater 26 Low
- Kiln 35 Low
Cooler losses 130 High
Heat of Reaction 400 None
Water Vaporization 4 None
Free Heat -20 None
Consumption 740
FIGURE 11
M::Jving Row
BRIDGINGPLATES (DEAD GRA TES)
Dead Grate
Bolt
FIGURE 12A
373
GRATE LINE CONFIGURATION
~ o o
Horizontal Cooler
,,,, .>
.--1'10
0
3
0
Slope Cooler
\
,
374
: -,
Inclined Cooler
FIGURE 12B
COMPARATIVE METHODS FOR GRATE LINE CONFIGURATION
Fuller
DIFFERENT METHODS FOR OBTAINING AN 10 PLATE INCLINATION TO GIVE
AN OVERALL HORIZONTAL GRATE LINE
Fa/ax
FIGURE 12C
375
I
,
INTERNAL WHEELS WITH GUIDE ROLLERS
FIGURE 13A
376~ ~ ~ - - - - -
FLS-STYLE INTERNAL WHEEL DESIGN
C""", pie!.
OustseeI
Grates,
Supporting roller
Cross beam Longitudinal
girder
Guide roller
FIGURE 13B
377
378
Second Generation GRATE COOLER
IKNPENDULUMSUSPENSIONSYSTEM
PEN'DULuMSU5PEN[)ED
FRAME
FIGURE He
~ ~ - - - - - - ~ ~ - - - - - - - : - - - - - - - - - - - - - - - . . . , . . . . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - : -
Second Generation GRATE COOLER
CLAUDIUS PETERS COMPACTSWING SYSTEM
I
I
I .
I
,
,
FIGURE 13D
379
380
EXTERNAL SPILLAGE VALVES
FIGURE 14
REDUCED FALL THROUGHGRATES
FIGURE 15
381
382
Second Generation GRATE COOLERS
HYDRAULIC GRATE DRIVE
Fuller Hydraulic Drive
CPAG Hydraulic Drive
FIGURE 16
CLINKER BREAKER
FIGURE 17
383
ROLL-TYPE CLINKER BREAKER
FIGURE 18
384
AUTOAIR FLOWCONTROL LOOP
Pressure Transmitter
@ Pressure Indicating Controller
@ Speed Actuator
Vari-Speed
Drive
FIGURE 19A
385
KILNHOOD DRAFT CONTROL.
Cooler
Vent Fan
Vari-Speed
Drive
Heat
Exchanger
Cooler
Kiln
Hood
~
~
@
<f)
~
~
Pressure Transmitter
Pressure Indicating Controller
Speed Actuator
FIGURE 19B
386 --------------0----------------;--------------
COOLER GRATE DRIVE CONTROL LOOP
-
. . Z}-----,,.---{
Hafio Bias Oontroller
PressureTransmltter
Pressure Indicating C o n t r ~ l l e r
.@ Speed Actuator
L- -{Fy}--'- ---..;J
FIGURE 19C
387
388
AIR BEAMTECHNOLOGY
FIGURE 20
First/Second Generation HYBRID SYSTEM
INTERNAL VIEW
If
I
loj i
I
FIGURE 21
389
Second Generation (Air-Beam) COOLER CONVERSTIONPERFORMANCE RESULTS
APRIL 1992-AUGUST1995
PLANT YEAR TPD SIZE GUARANTEE
1 1992 2000 9 Row CFG 22 kcal/kg Savings 29 kcal/kg Savings
2 1992 2200
9 RowCFG
20 kcal/kg Savings . 57 kcal/kg Savings
9 Row RFT
9 RowCFG
58 kcal/kg Savings
3 1992 1900 9 RowRFT 20 kcal/kg Savings
PfH Modif.
6.9% Capacity Increase
4 1992 5000 23 Row CFG
40 kcal/kg Savings 68 kcal/kg Savings
1.75 kWhiT Reduction 2.2 kWh/T Reduction
5 1992 2000
18 Row CFG 1500 to 2000 TPD
2200 TPD Actual Capacity
PfH Modif. Capacity Increase
6 1993 850
9 RowCFG 8.0% Increase of Recuperation
19.4% Increase of Recuperation Eff.
8 RowRFT Eff.
7 1993 1060
17 RowCFG 49 kcal/kg Total Cooler Loss 39 kcallkg Total Cooler Heat Loss
19 RowRFT 6.6 kWhiT Total Power 6.5 kWhiT Total Power
8 1993 5800
36 RowCFG
40 kcal/kg Savings
80 kcal/kg Savings
22 RowRFT 9.4% Capacity Increase
9 1994 1950
18 RowCFG
4.8% Capacity Increase 6.5% Capacity Increase
PfH Modif.
10 1994 4600 32 RowCFG 60 kcal/kg Savings
70 kcal/kg Savings
8.1 % Capacity Increase
FIGURE 22
390
KILN- COOLER RELATIONSHIP
FIGURE 23A
391
392
CONVENTIONAL COOLER AIR DISTRIBUTION
FIGURE 23B
BED DEPTHEFFECT ON COOLING
THIN BED
OPERATION
"'" I KILN
.----r-...../ ROTATION
I
I
THICK BED
OPERATION
FIGURE23C
393
COOLING CLINKER WITH ONE COMPARTMENT COOLER
CLINKER
BED
COOLING
CURVE
AIRFLOW
CURVE
PRESSURE
CURVE
394
1
FIGURE 23D
COOLING CLINKER WITHFOUR COMPARTMENT COOLER
COOLING
CURVE
CLINKER
BED
L--I-_---J. --L- ]_
I ~ . , - - - " , , - _ ~
I
i
I
I I
I
I I I
~ I
~
I . - - - - ~
AIRFLOW
CURVE
.-{--_----'--_l
PRESSURE
CURVE"
-I
3
..--
I
I I
'4
I
1 ~ 1 1 2 ~ I - . - - - - _ ~ ]+-1-------+
FIGURE 23E
395
' ....
'(ll
0;..
:,x
' ....
, Q;'
c
...
,"C
"al'
...
:::l
rtI
.rtI
2:!
C.
RED RIVER
top r,ossclinker bed
based Ergun's equ.
.
.-
--
,
./
/ /'
/ I, ,
If I---'"
/
-- ------
---'
IJ
I //
_.Op':
_Op=a.".()OSCH
_ Dp = o-.Q-1Co 1M
_ op =l).l}1S rM
396
1,00
Ve 10city [m/s]
FIGURE 24
ELEVATED RESISTANCE GRATE PLATES
FIGURE 25
397
398
TYPICAL AIR BEAMASSEMBLY
FIGURE 26
STATIONARYINLETSECTION
FIGURE 27
FlOw
". . . /
399
COOLER LOSS
HEAT LEAVING THE COOLER AS
SENSIBLE HEAT WITH THE CLINKER
HEAT LEAVING THE COOLER WITH THE
EXCESS AIR
HEAT LEAVING THE COOLER AS
RADIATION
FIGURE 28
400
COOLER LOSS AND RECUPERATIONASA FUNCTION OF
COMBUSTIONAIR REQUIREMENT
90
80
z
0
-
...
<l:
70
n::
w
a..
:::J
U
w
60
n::
I-
w
:l: 50
~
40
~
----
...........
! I
I
r-,
r-.....
,.....
1_-
- - ~
- ~ - ,
I'-.
'"
r----...
:-..
I
"
........... K./1.
"I'---
r-,
r-;
r---....
-....
I
l-
I--
~
1'-.'
r-,
-
--...
.......
r-Q
~
r-
:---r- --,
r-..
"
r-,
<,
I'-...
<,:--...
1""-"<
~ ' - -
C'+--
-
I'--
<,
r-,
: r - ~ r--
--
r---
........ r- fo.,.
-
.... r-.........
I
. -.
I'-...
! r-. I "I
r--
--
<,
r-,
I'"
fL....
r--
...........
l""'-
I
.::l-1
r--_
r-
I ~
~
-I-
I
,
, ~
1.3
1.3 12 1:1 1.0
0.9
Q9
0.8
0.8
I
-
I ~
~
~
-
I-
.,-
~
-.
V
--
l.-'-
V '" ~
V
....
.-
,/
-"
~
~ - -
./ .-/
..-'--
V ./
V
lP
;;.-
---
--
~
....
- --
V
:
----
~
~ ...........
......-
..-
/
./
/"
V
----
V (J$
"""
!--
/
.,/
-
V
--
--
V
~
V
.-
~
~
--
.I ./
",.
V
V
l-
V
V
V
V
.... V .-
V
.......-
V
V
-- V
.....
........
V
200
180
1GO
140
120
100
80
60
40
20
o
100
(f)
(f)
o
'..J
'0:
W
....J
o
o
u
-
..J
U
COMBUSTION AIRrROM COOLERKG/KGCLINKER
FIGURE 29
401
COOLER LOSS
COOLER RADIATION LOSS
HEAT IN CLINKER FROM COOLER
HEAT IN EXCESS AIR FROM COOLER
A. TOTAL COOLER LOSS
REFERENCE TEMPERATURE = DOC
CLr=
+
+
+
Q IN CLINKER FROM COOLER
Q IN EXCESS AIR
QINHOT AIR
RADIATION
B. VDZ COOLER LOSS (also known as NET Cooler Loss)
REFERENCE TEMPERATURE = COOLING AIR TEMPERATURE
CLvDz =
+
+
+
Q (CLINKER FROM COOLER) - Q (CLINKER AT COOLING AIR TEMPERATURE)
Q (EXCESS AIR) - Q (EXCESS AIR AT COOLING AIR TEMPERATURE)
Q (HOT AIR) - Q (HOT AIR AT COOLING AIR TEMPERATURE)
RADIATION
C. STANDARD COOLER LOSS
COOLER LOSS INDEPENDENT OF KILN SYSTEM
NORMALIZE:
COMBUSTION AIR REQUIREMENT = 1.15 kg/kg clinker
COOLING AIR TEMPERATURE = 18C
FIGURE 30A
402
COOLER EFFICIENCY
A. The cooler efficiency to be defined and calculatedas follows:
IJ cooler = 100
Where:
100 x Cooler Loss. %
1450 X SK
1450
+ (M
c A
X TCA X SA
TCA
)
Cooler Loss = TKO XSKTKO + MEX XTEX XSA
TEX
+ RA
MCA = kg of cooling air per kg of clinker
MEX = kg of excess air per kg of clinker
TC = temperature ambient (of cooling air)
TEX temperature of excess air
TKO temperature of clinker leavingthe cooler
SAT = specific heat of air at temperature T"C
SK
T
= specific heat of clinker at temperature TOC
RA = cooler housing radiation in kcal/kg of clinker
Reference Temperature= OC
B. VDZCooler Efficiency
Referencetemperature = cooling air temperature
E =100 _ 100 x (Cooler Loss - Fan Power)
voz Maximum Heat Release Clinker
Where:
MaximumHeat Release is defined as the heat content of clinker at the kiln discharge
temperature (arbitrarilydefinedat a temperature rangingfrom 1350Cto l450C) minusthe
heat content of clinker at the ambient temperature .
C. . Nominal cooler recuperation reference temperature = OC
R = QSECAIR +Q
TERT
AIR x100
QCLlNKER 1450,C + QCOOLINGAIR
FlGURE30B
403
VDZ COOLER LOSS vs. AIR FROMCOOLER TO KILNSYSTEM
........... ; .
1.5
1.45
1:3 1.4
1.25 1.35
kg/kg cl.
0.9 1 1.1 f 1.2
0.85 0.95 1.05 1.15
Secondary & tertiary air
0.7 0.8
0.75
, .. .
:t:: .::::....7 _
! ! !! ! i I!
o
OJ
---- CO
o
(j)
(j)
o
'-
Q)
o
o
U
FIGURE 31
404
TYPICAL RED RIVERS
October 1998
May 2000
FIGURE 32A
405
I
406
SNOWMANFORMATION
FIGURE32B ---------------------
AIR-BEAMSTYLE STATICINLET GRATE
FIGURE32C
407
TYPICAL AIR-BEAMSTYLE COOLER
WITHSTATICINLET GRATE
FIGURE 33
408
6
12
o
ELEVATION VIEWOF CFGICIS AIR-BEAM1278 COOLER
CD
...
.. ~ ,. ' ~ '" "' .. '" " ..... ;. fl '. '" ..
'J ,'\ ~ _ ,1 <J ill ;. e u "
... 1'1 l' "l I'll It " ~ r; r;- ~ 10 .- ,., ,. : ~ " ,. " ., "I "1 " " t! r- '" - ,., '" ., '1 '"' .. -1 .... l' n ... ,., ,,' "" '" r-: .. .. '. 'J <: 'I
.. - It .. 'l '.' ~ It " ... __' ...~ '" " ~ Jt III fI " II lI. " .. t;, ...0 .1 d " " .:;. ,.; .. " lJ I; ..... ". " ... , ...... OJ_ :i
SSSSSSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMSSMS
cr
FIGURE 34
409
TYPICAL First Generation GRA TE COOLER BALANCE
CONVENTIONAL
Radiation
11 kcal/kg
Excess Air
2.00 kg/kg
265C
130 kcallkg
a a a a ~
a
a
Kiln Exit
1450't
383 kcallkg
a
a
Tertiary Air
0.65 kg/kg <} a a "a
750C a
a
124 kcal/kg a
a
a
a
a
a
..
a
a
a
a
a
Secondary Air
0.45 kg/kg
1070 c
126 kcal/kg
Cooling Air
3.10 kg/kg
35C
26 kcal/kg
a
"a
aconaccQ
Clinker
1.00 kg/kg
100C
19 kcallkg
TOTAL COOLER LOSS: 160 kcallkg
STANDARD COOLER LOSS: 130 kcal/kg
FIGURE 35
410
TYPICAL Second Generation GRATE COOLER BALANCE
AIR BEAMDESIGN
Radiation
11 kcal/kg
Excess Air
1.45 kg/kg
270C
95 kcal/kg
o
o
~ o o o o $ >
o
o
o
o
o
o
o
o
o
o
o
o
o'
Kiln Exit
1450 "c
383 kcal/kg
o
o
Tertiary Air
0.65 kg/kg <l 0000
815C 0
o
135 kcal/kg 0
o
o
o
o
o
o
o
o
o
o
Secondary Air
0.45 kg/kg
1220 c
145 kcal/kg
Cooling Air
2.55 kg/kg
35C
21 kcal/kg
o
o
o
o c a c n e c c
Clinker
1.00 kg/kg
100C
19 kcaVkg
TOTAL COOLER LOSS: 125 kcallkg
STANDARD COOLERLOSS : 100 kcal/kg
FIGURE 36
411
412
FIGURE 37
FIGURE 38
413
414
High Bed
Resistance
Lower
Valve !\P
FIGURE 39
Low Bed
Resistance
FIGURE 40
415
Third Generation (SF CROSS-BAR)GRATE COOLER
FIGURE 41
417
- - - - - - - - - - - - - - - ~ - - - - - - - - - - - ~ - - - - - - ~ - - - - - - - - - - - - , - - - - - - - - -
Third Generation (SF CROSS-BARTM) GRA TE COOLER
..
...
.----- ----"-....
FIGURE 42
419
,
Third Generation (SF CROSS-BAR") GRA TE COOLER
FIXED GRATE LINE
FIGURE 43
421
LOWER
VALVE L1P
Third Generation (SF CROSS-BAR") GRATE COOLER
~ W B E D
RESISTANCE
HIGHER
VALVE LlP
FIGURE 44A
423
MECHANICAL FLOWREGULATOR CHARACTERISTICS
100
90 J -
. - .
80 -
. -- - ----. ..
- ~ --- - ..- ,- ...-- -
......
N
70
E
-
~ . - --0,- - _______
- .- -. -_.- -r
--]
-c:
60
E
~ .- - - ~ - ..
-
I
Ol
50
,:;,c ~ - _ ... - -..
....... ..
S
40
I
0
.....J I
LL
30 - -
--__A
---- -
.. ~ . -- -
-
I
0::
I
20 ------ ".
. . ---_ .. _--- .- . .
_. - _.
r
10
I
a --'
a 50 100 150 200 250 300 350
PRESSURE DROP ACROSS REGULATOR [mmWG]
(Variation in Clinker Bed Resistance)
FIGURE 448
425
FIGURE 45 A:
Fl.Smidth - Cross-Bar Cooler
FIGURE 45 B
Claudius Peters - ETA-Cooler
FIGURE 45 D:
KflD's - 3
rd
Generation "Pyro Floor" Cooler
427
FIGURE 46A
Drives Move in Unison
FIGURE 46 C:
Second Drive Retracts
FIGURE 46 B:
First Drive Retracts
FIGURE 46 D:
Drives Move in Unison
429
FIGURE47A
FIGURE47B
431
FIGURE 48
433
TYPICAL Third Generation GRA TE COOLER BALANCE
SF CROSS-BAR'" COOLER
Radiation
11 kcal/kg
Excess Air
1.05 kg/kg
295 DC
75 kcaVkg
Clinker
1.00 kg/kg
100 DC
19 kcal/kg
~ O O O O $ >
o
c
c
o
tr
o
o
n
o
o
o
o
o
Kiln Exit
1450
DC
383 kcal/kg
-
aOjD:-:O;1r;
o
o
Cooling Air
2.15 kg/kg
35
DC
18 kcal/kg
ll!=:[= = ~
Tertiary Air
0.65 kg/kg <J c c DO
870 DC 0
c
145 kcal/kg o
c
o
a
o
c
c
c
o
L ~ : ..;:;- _
Secondary Air
0.45 kg/kg
1260 DC
150 kcal/kg
TOTAL COOLER LOSS: 105 kcalfkg
STANDARD COOLER LOSS: '85 kcallkg
FIGURE 49
435
OMPARISON OF First. Second. Third Generation GRATE DIFFERENT COOLER TYPES
FIRST FIRST/SECOND SECOND THIRD
PARAMETERS
GENERATION GENERATION GENERATION GENERATION
Conventional
Hybrid Cooler
Air-Beam Cross-Bar
Cooler Cooler Cooler
Fuel (kcal/kg elk) 745 722 710 692
Stage I Temp. (0C) +20C +12C +7"C
_oC
Stage I Press. (mrn WG) +8.0% +4.7% +2.7% -
Operating Kiln J.D. Fan (kW/mt) 6.03 5.97 5.78 5.49
Air for 80C + Ambient (kg air/kg elk) 2.90 2.50 2.35 2.10
Standard Cooler Loss (kcal/kg elk) 130 110 100 85
Operating Vent Fan Volume (m
3/hr)
245,000 201,000 182,000 151,000
Operating Cooler Vent Temp. 286C 305C 298C 321C
Operating Cooler Vent Fan Power 1.22 kW/mt 0.97 kW/mt 0.88 kW/rnt 0.72 kW/mt
Clinker Cooling Fans Operating Power 4.80 kw/mt 4.77 kW/mt 4.70 kW/mt 4.28 kW/mt
FIGURE 50
437