Documente Academic
Documente Profesional
Documente Cultură
Process Instruction
Date: 30-07-2015
Created by: BIDE
List of contents
1.0 General notes ..................................................................................... 3
2.0 Construction and operating principle ....................................................... 4
3.0 Safety and protection ........................................................................... 7
4.0 Preparations before operation ................................................................ 8
5.0 Operation ......................................................................................... 10
6.0 Operational controls ........................................................................... 16
7.0 Operating parameters and alarm limits ................................................. 18
NOTE!
The present instruction manual is concerned with the situations which, according
to the experience of FLSmidth, are the most likely to occur. An exhaustive
enumeration of all conceivable situations, which may occur during manufacture,
installation, operation and maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen
in the instruction manual, and which the operator is/or feels unable to handle, it
is recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.
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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 2 of 21
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Process Instruction: 70031181-1.0
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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 3 of 21
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Process Instruction: 70031181-1.0
Design specifications
Cooler inclination 0
The cooler nomenclature, in the table above, describes the number of grate plates
(width x length) that the cooler consists of and includes the inlet section.
2.2 Operating principle
The clinker leave the kiln at around 1450 C and fall down onto the cooler inlet
zone, after which they are transported slowly down through the cooler. While being
transported through the cooler the clinker are constantly exposed to a cooling air
stream from below with the purpose of cooling down the clinker as well as
recuperating heat back to the kiln system.
The cooling air is provided by the fans installed for the cooler. When the cooling air
passes up through the clinker bed, it is heated by the clinker and for the first part
of the cooler the heated air is drawn back into the kiln system and used as
combustion air. Approximately 45 % of the total cooling air is returned back to the
kiln system and recuperates approximately 75 % of the clinker heat back to the kiln
system. The remaining air is extracted as excess air from the cooler.
The excess air extracted from the outlet end of the cooler and is dedusted in the
cooler excess air filter. The clinker dust from the cooler filter is transported to the
clinker conveyor.
At the outlet of the cooler a clinker crusher is installed for breaking the lumps larger
than ~25-30 mm
2.3 Construction principle
The grate systems for the CrossBar cooler is comprised of:
Cooler inlet section
Cross-bar sections
The air from the cooler fans is distributed throughout the cooler with each fan
supplying air to its own air compartment.
2.3.1 Cooler inlet
The inlet grate area is made up by casted grate plates. The grates are placed in a
sloped angle to promote clinker flow. The air flows out horizontal from the grates
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Process Instruction: 70031181-1.0
though a number of aeration holes. The grates have smooth surfaces which
together with the forward facing air slots promotes the flow of clinker during
operation. Blast air is directed through the grates and is channeled out through the
grates horizontal air sloths.
Air blasters are also installed in the cooler inlet wall. There are a series of air
blaster channels (ABC). The selection of ABCs can be changed during operation, as
also the sequence of shooting can be changed during operation. One air blaster is
installed to blow kiln sealing dust back into the cooler.
A casting curb on each side of the cooler inlet is provided to achieve a better clinker
distribution on the grate area. (Casting curb = called a horse shoe, a specially
formed refractory side wall).
For temperature protection and monitoring, some of the ADPs are equipped with
thermocouples for measuring the grate plate temperatures. These temperatures
can be monitored from CCR.
2.3.2 Cross bar sections
The cross bar section consists of the fixed grate plates with the cross bar transport
system located above the grates.
Below the grates the cooler is divided into under grate compartments (UGCs), each
being supplied with air from their respective cooler fan attached.
2.3.3 Mechanical flow regulator (MFR)
Each grate plate for the cooler is equipped with an MFR (mechanical flow regulator).
The mechanical flow regulator limits the air flow though the grate by varying its
pressure resistance.
The MFRs come in various capacity ranges, which make it possible to create an
airflow distribution pattern to suite a specific clinker granulometry. Therefore,
several sizes of MFRs can be found within the same section.
The MFR is described by two characteristics:
1. Maximum pressure drop compensation capability
2. Flow rate maintained within this pressure range
The MFRs are marked with 5 to 7 digit identifiers.
The first 4 to 6 digits show the flow of kg/m/min and the last digit shows the
range of differential pressure of operation in hundreds of mmH2O. The m refers to
the area of the grate plate where the MFR belongs.
Examples:
MFR type 40404, has a flow rate of 40 to 40 kg/m/min with a differential
pressure of 400 mmH2O range of operation
MFR type 1201204, has a flow rate of 120 to 120 kg/m/min with a
differential pressure of 400 mmH2O range of operation
When the MFR regulator is moving at approx. 10 - 45 angle the air though the
grate is according to the MFR nominal flow.
If the installed MFR pattern is not suitable for the long-term production level or
characteristics of the clinker, the MFRs can be changed to match the actual needs.
The plant personnel should keep track of any changes performed.
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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 5 of 21
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Process Instruction: 70031181-1.0
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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 6 of 21
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Process Instruction: 70031181-1.0
Lock out and tag out the following equipment before working on the cooler
Kiln
Kiln drive
Kiln feed
Fuel to kiln
Primary air fan (kiln)
Preheater ID fan
Cooler
Air blaster cannons
Cooler drives
Cooler fans
Clinker crusher
Clinker transport
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A Inspect grates
o Ensure plates are not blocked so air may pass though as
intended
o Grates must be free from debris (steel, refractory, castable,
etc.)
Measure cooler wall height reference points
o Height from the grate line to a number of wall reference
points are measured, enabling clinker layer height to be
visually determined during operation
Check installed MFR's
o MFRs should move freely
o MFR layout must be checked to match the design layout
All doors to the cooler compartments and cooler must be closed
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Process Instruction: 70031181-1.0
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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 9 of 21
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Process Instruction: 70031181-1.0
5.0 Operation
5.1 General
The two prime objectives of the grate cooler are as follows:
To cool the clinker
To recuperate heat from the clinker back to the kiln system
In normal operation the objectives above are achieved by slowly over moving the
clinker through the clinker cooler over a period of approximately 25 minutes, while
aerating the clinker layer from below with a proportionate air flow of around
1.8 Nm/kg clinker.
5.2 Starting up
To provide air for the kiln burner at the initial heating up, a few selected cooler fans
can be started up slowly according to the air demand of the kiln.
Gradually as the clinker begins to leave the kiln, the grate cooler must be put into
operation.
1) Start the clinker transport
2) Start the dust conveying system for the excess air handling equipment
3) Start clinker crusher
4) Start the cooler excess air fan
a) Adjust the negative pressure in the kiln hood to about 0.5 mbar and set the
PI(D)-regulator in automatic mode
5) Start all cooler fans not already operating
a) Maintain all compartment pressures above their minimum alarm setting (20
mbar for the inlet and first two compartments and 15 mbar for the rest)
6) To avoid a build-up of clinker on the grates
a) Cooler drive can be started stepwise with the increasing material flow from
the kiln
7) Gradually as the production increases
a) Cooling air is increased
8) Start the cooler drive
a) Continuous operation beginning with minimum stroke speed
b) The cooler drives must be in operation before the kiln drive can be started.
This interlock can be overruled during the heating-up period.
Note!
It is desirable to place the cooler excess air fan in automatic mode as early into the
preheat mode as possible. Once the excess air fan automatically controls the kiln
hood draft, it is easy to bring any remaining undergrate fans on line.
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Note!
Operate with min. 20 mbar on the inlet and the first two cross-bar compartments,
and min. 15 mbar on the remaining. This will protect grate plates from blocking and
ensure clinker is not forced backwards though the grate plate and into the under
grate compartments.
An optimization of the clinker bed depth will take place when the kiln performance
becomes more stable.
If the clinker tends to accumulate excessively on the inlet area, or if agglomeration
of clinker occurs, the air blasters can be programmed to shoot more frequently to
facilitate movement of the clinker, and to avoid agglomeration.
5.3 Operation
5.3.1 Clinker layer
The clinker layer in the cooler is controlled by the speed of the cooler drive. This
speed is controlled by means of the ratio between two pressures:
1) The average pressure in the rectangular tower between the air distribution plate
and MFR in the first crossbar undergrate compartment (plate pressure), in a
ratio 50-100%
2) The pressure of the fixed inlet undergrate compartment, in a ratio 0-50%.
The combined fractions of the two pressures should always add up to 100%.
The set-point for this controller will in automatic mode maintain the clinker bed
depth accordingly:
Decreasing bed depth; the combined pressure will decrease, and the speed
will reduce
Increasing bed depth; the combined pressure will increase, and the speed
will increase
In case the controller is in manual mode, for example in case of a flush from the
kiln, the cooler drive speed should be changed very slowly, i.e. 0.5-1 stroke/minute
at a time. It is normally recommended to try to maintain a normal drive speed and
do not overreact as long as the cooler fans can keep the airflow set-point. A rapid
change, especially if increasing the stroke speed, is likely to reduce the clinker layer
too much and expose the cross-bars or even the cooler grate plates to excessive
temperatures, which can damage them.
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It is important to maintain a consistent clinker bed in the cooler. If the bed is too
low the retention time of the clinker in the cooler will be too short, and that will
affect the clinker temperature and heat recuperation.
5.3.2 Cooler fans
Shortly after startup of the cooler, the fan flow control should be placed in
automatic mode for maintaining sufficient airflow to the UGCs.
The set point of the airflow control must gradually be increased as the clinker bed
depth is reaching the desired level of typically 600 mm.
5.3.3 Visual inspections of undergrate area
Regular, periodic inspections of the under-grate area are made from the outside
though the view ports. Ensure the MFRs are operating freely, that there is no
clinker fall-through into the compartment, and that there is no leaking of hydraulic
oil from the hydraulic system.
During normal operation, also bolted connections in the under grate compartment
should be monitored. During startup, frequent inspections are required.
Note!
Leaking of hydraulic oils in the undergrate compartments will lead to dust buildup
inside the grate plates and hereby reduce the airflow though the plates, and may
also stop the MFR's from moving freely. Stop the hydraulic leaks as soon as
possible to avoid loss of cooler operational performance.
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At low air flows the clinker will begin to agglomerate and stick to each other,
causing poor clinker distribution from inlet to the crossbar sections and hereby poor
cooler performance and risk of clinker buildups ("snowmen" formation). At high air
flows the cooler recuperation will be reduced.
The fixed inlet should have just enough air so that the clinker does not agglomerate
during normal operation. Check and adjust the air flow to the fixed inlet while
observing the clinker layer (inspect from outside the cooler though viewports).
5.4 Trouble shooting guide
5.4.1 Low bed depth
The cooler drive speed is too high. Reduce the cooler drive speed and/or increase
the set-point pressure which controls the cooler drive speed.
Difference in clinker granulometry may lead to different pressure loss for same
layer depth and air flow.
5.4.2 MFR regulators fully open
Not necessarily a problem. The air flow passing by the MFR's is less that the
nominal MFR capacity.
The normal case would be that at least a few of the MFR's in the chamber would
move just a little, depending on how close the applied air flow to the compartment
is to the MFR's total nominel capacity.
Verify that the desired airflow is being delivered to the air compartment by
checking the fan power, flow, pressure and piezometre set-point.
5.4.3 MFR regulators fully closed
The air flow though the MFR's is same or larger than the MFR's nominal flow
capacity. It is not possible to get more air into the compartment, as the MFR's will
counter any such attempt, and the result would only be an increased power uptake
of the cooler fan.
Should more air be required to the compartment, the MFR's will have to be
modified or changed, to suit a required larger flow.
5.4.4 Clinker fall through
Check actual compartment pressures are above the min. of 15 - 20 mbar. If the
pressure is too low, pressure must be increased by increasing the fan air flow
and/or clinker bed debt.
If fall through is occurring and is persistent, the cooler must be stopped and
mechanically inspected for faults.
5.4.5 Caking or crusting of the clinker bed
The airflow, especially on the inlet, should be increased to ensure proper cooling of
the clinker which should prevent clinker agglomerations.
5.4.6 Poor material distribution on the inlet
The distribution of clinker is dictated by the amount of inlet airflow, and the grate
speed. If clinker build-up formations occur in the cooler inlet area, increase air
blaster sequence time or switch air blast channels to problem areas.
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Low compartment pressure Indicates low air flow though the grates.
Crossbar drive is stopped on interlock.
High excess air temperature Increase the cooling air to the cooler.
ID fan speed forced down or Cooler fan air flows are forced down by interlock to
stopped pre-set default speeds (or damper positions), which
have been set individual for each fan (typically
around 40 to 60 %). Cooler air fans are set to
manual control.
If the kiln stop lasts for more than a day, the cooling fans are stopped, when the
clinker inside the cooler has been cooled sufficiently to avoid heat damage to the
clinker cooler.
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Note!
The cooler should not be emptied for material, unless this is necessary in order to
carry out repairs. For repair works, it is only necessary to empty out material in
local areas.
Maintain a normal layer of clinker in the cooler, until the kiln has been cooled off
completely, and inspection has been carried out in the kiln.
After eventual repairs in the kiln, and discharge of old lining or crust are finished
first then will it be practical to empty out the cooler.
Emptying of the cooler by means of the grate drives must be done with great care.
The clinker bed should be visually monitored during emptying out, and the grate
must be stopped, when the crossbars get visual. The remaining clinker must
hereafter be removed by other means than the cross bar drive.
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Cooler fan air flows Fan speed control (or damper if installed)
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Kiln speed < 1.5 Cooler inlet shock blaster program is stopped
(auto start if conditions are not fulfilled)
Fixed inlet pressure < 45 mbar
Preheater ID fan Stopped or forced Cooler fan flows reduced to a default speed
down setting/damper position (typical around 60 %)
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x The normal value is either given in above text or has to be evaluated during
commissioning
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Operating and
alarm limits
Expected value
Manual control
Max. 3 Alram
Max. 1 alarm
Max. 2 alarm
Control loop
Min. 1 alam
Min. 2 alam
Alarm
Kiln hood mbar -1 0 1)
C 1050
Grate temp. C x a)
Compartment 1 mbar x 2)
stoke/min x 2)
m/min 370 + 4)
kW 62
m/min 736 + 4)
kW 120
m/min 826 + 4)
kW 126
m/min 781 + 4)
kW 111
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m/min 758 + 4)
kW 107
m/min 765 + 4)
kW 92
Amps. x
Amps. = Current
1
dP
273.15
35.244
where
Q Normalized flow in Nm/min
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Process Instruction: 70031181-1.0
F Flow constant for the venturi (0.63 for standard FLS type)
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