8/12/2019 Clinker Cooler Types

1/17

8/12/2019 Clinker Cooler Types

2/17

From

Clinker

Cooler

Clinker

Temp.

1400oC

Reduces

100 .. 200oCTo

8/12/2019 Clinker Cooler Types

3/17

Cooler Thermal Efficiency:

100*A

B-A=Notation:

A = Heat content of clinker leaving the kiln

Heat losses of clinker coolerB =

B consists of =

Heat loss in cooler exit airHeat loss in clinker leaving cooler

a =

Heat loss by radiation

b =

c =

8/12/2019 Clinker Cooler Types

4/17

Items influence the efficiency

The clinker must be brought in an intensive contact

with the cooling air

The quantity of available cooling air affects the

efficiency

The efficiency is not only determined by the machine

itself, but also by the amount of cooling air.

The granulometry of the clinker affects the cooling

efficiency

8/12/2019 Clinker Cooler Types

5/17

Rough guideline for the Heat Balance

Heat input by clinker 1200oC 100%

Heat output

By secondary air 750oC 68%

By shell losses 22%

By clinker outlet 170oC 10%

8/12/2019 Clinker Cooler Types

6/17

Types of cooler

Grate Cooler

Rotary Cooler

Planetary Cooler

8/12/2019 Clinker Cooler Types

7/17

Set of tube fixed to the kiln, therefore no

separate drive required

Internal heat transfer equipment (lifters)

Planetary Cooler

No waste air

Capacities of up to 5000 t/d maximum,

preferably up to 3500 t/d

Not suitable for AS pre-calcining systems

8/12/2019 Clinker Cooler Types

8/17

Planetary Cooler Internals

8/12/2019 Clinker Cooler Types

9/17

Temperature Profile of Planetary cooler

8/12/2019 Clinker Cooler Types

10/17

Planetary Cooler

8/12/2019 Clinker Cooler Types

11/17

Rotary Cooler

8/12/2019 Clinker Cooler Types

12/17

Separate tube with separate drive

Internal heat transfer equipment (lifters)

Rotary Cooler

No waste air

Capacities of up to 4500 t/d maximum,preferably up to 2000 t/d

8/12/2019 Clinker Cooler Types

13/17

Design of Rotary Cooler

Diameter of the cooler is similar to that of a

corresponding suspension preheater kiln.

Rotating speed is in the same range as for the kiln (max.3 rpm)

The length to diameter is approximately 10

The inclination is comparatively high

in the order of 5%

8/12/2019 Clinker Cooler Types

14/17

Internals of Rotary Coolers

8/12/2019 Clinker Cooler Types

15/17

Cooling

Performance

he cooling efficiency ( heat recuperation ) is

equal or even slightly better

than on a planetary cooler.

ADVANTAGES

DISADVANTAGES

Simplicity of cooler design, robust piece

of equipment.

No special mechanical problems (at least

not more problems than on a rotary kiln).

No control loops.

Easy commissioning.

No waste air and therefore no de-dusting

equipment required.

Electrical energy consumption is approx.

5 kwh/t lower than for a grate cooler.

Rotational speed can be adjusted and

therefore upset kiln conditions can be

handled more easily than on a planetary

cooler.

itable for pre-calcining system having a

parate tertiary air duct (extraction of hot air is

ssible).

1. Little experience available with

large coolers (above 2000 t/d).

2. Formation of buildups

(snowmen) in the inlet chute. A

water-cooled chute or a dislodging

device is required in such a case.

3. Clinker outlet temperatures tend to

be high and therefore water

injection is usually required.

4. Due to large falling height wear

protection in the tube must be

reinforced (compared to a planetary

cooler)

5. High kiln foundations are required.

6. Cooler inlet seal can contribute to

additional false air inlet.

8/12/2019 Clinker Cooler Types

16/17

Specific Load

Where :

dm

t

LxDn x

PloadSpecific

2.51.5

P = Clinker production in t/24 h

Number of coolers tubesN =

L = Length of cooler tubes in m

Cooler tube diameter in mD =

8/12/2019 Clinker Cooler Types

17/17

To avoid dust circulation

Dx4

n x

P

2 < 70 t/m2