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clinker cooler operation
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CLINKER COOLER
CLINKER COOLERReduce clinker temperature from approx. 1400 oC to approx 100 ~ 200 oC The heat of the incoming clinker is recuperated in the secondary air of KilnAn efficiency of incoming clinker heat usually lies within 65 ~ 75%
Clinker Cooler TypeGrate CoolerCross flow heat exchange through clinker bed with cold airGrate movement : reciprocating; consisting of movable row (reciprocating) & fixed rowGrate can either be horizontal or inclined (3o)Occurrence of waste air requires additional equipment for dedustingCapacities of up to 10,000 tpdRotary CoolerSeparate tube with separate driveHeat transferred by internal equipment (lifters)No waste airCapacities of up to 4,500 tpd maxPlanetary CoolerSet of tubes fixed to the kiln no separate drive requiredHeat transferred by internal equipment (lifters)No waste airNot suitable for separate tertiary air duct precalcining systemCapacities of up to 5,000 tpd
INCLINED COOLER (Claudius Peters)
PYROSTEP GRATE COOLER (KHD)
MAINTENANCE for GRATE COOLERDriving Mechanism :MechanicalHydraulicalGrate Frame MechanismDriving Support (incl. Wheel, rail, bearing, sealing plate)Driven Support (incl. Wheel, rail, bearing, guide wheel)Ceiling Chamber : air leakagePartition plateExpansion jointGrate Plate & Air BeamGrate plate worn out, bolts looseness, side plateAir beam: deform, bolts loosenessDischarge Hopper & Flap DamperDrag Chain Mechanism (e.g : chain condition, bearing, coupling)Cooling Fan Mechanism (e.g : bearing, impeller, suction cone, coupling)Clinker Crusher (e.g : grizly bar, hammer, disc, bearing, driving)Casing, castable, bullnose
DRIVING MECHANISMMechanicalHydraulical
DRIVING SUPPORT FRAME
DRIVEN SUPPORT FRAME
GRATE PALTE & AIR BEAM
Omega-plate with wear protectionThrust area and thrust edge made out of extreme wear resistant compound material with heat resistant basic material with hardness of 63 HRc
Discharge Hopper & Flap Damper
Clinker Crusher
Bull Nose Cooler
Bull Nose Cooler
Bull Nose Cooler
Smith Fuller Cross Bar Cooler
Air Distribution Plate with Mechanical Flow Regulator
Cross Bar InstallationDistribution of air is optimized for all mode of operationMaximum availability and minimum maintenance (no movable grate plate, only reciprocating cross bar) No fall through of clinker & no undergrate conveying system is requiredStatic clinker layer protects air distribution plates against wear and heat, so plates will remain in service for a long time
Reciprocating Cross Bar and Stationary Clinker Layer
Rotary Cooler
Inside Rotary Cooler
Lifter Rotary Cooler
Planetary Cooler
Maintenance for Planetary CoolerInlet Cooler :Cracking at neck areaInlet segment conditionCooler Elbow :Elbow ConditionExpansion jointCooler Tube, Support and Outlet Casing :Fixation condition (fixed side and loose side)Cracking and wearing ConditionInternal Part : Breaker, Scattering and Lifter CoolerClinker Crusher (e.g : grizly bar, hammer, disc, bearing, driving)
Zone 1Breaking zoneIncrease specific surface of clinkerZone 2, 3 & 4Breaking up effect of the clinkerand segregation capabilityZone 5Maximum Lifting areaLow secondary air speed, creates low dragging kinetic energy against fine clinker
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