LATEST ENERGY EFFICIENT CLINKER

COOLING TECHNOLOGY AND

OPERATION -FONS DELTA COOLER
 Content
• Modular Design
• High Efficient Transport system
• STAFF – For higher Thermal savings
• Lowest Shutdown time concept
• Operational excellence with Zero spillage
• Lowest Maintenance cost
Modular design
 Walking Floor Cooler,
invented in 1999 by Mr.Fons
 Walking Floor Cooler

Horizontal clinker transport =>

no Red River Flowing

Adjustable stroke length for each lane =>

Increase heat recuperation

High transport efficiency =>

Low speed
 Benefits
• Stationary clinker to protect the grate line
• Grate and Seals not a wear item!-
Linear Motion
More than one century
Four Joints Mechanism
Four Joints Mechanism
 Benefits
• Sealable
• High reliablity
• Easy maintenance,
• Central automatic greasing system
• Cost effective installation
Heat Recuperation
Is there a choice?

STAFF
Stepped Air Flow Function
 STAFF
Spring loaded Valve with adjustable orifice – every grate plate 400mm x 400mm
 STAFF
High clinker resistance Lower clinker resistance Lowests clinker resistance

No STAFF resistance 50% STAFF resistance 100% STAFF resistance

 STAFF
Adjust air-flow setting with out
spare parts and in operation by
just reposition orifice.
Flow possible above 100%
resistance – with out fixed
orifice opening. For upside
condition of kiln.
 Economic Benefits
• Having a STAFF (but not on the payroll) serving you 24-
7, giving you automatic optimal heat recuperation
• Lower compartment pressure => saving electricity
• One STAFF for every Grate Plate (400x400 mm)
 Workshop Assembled
Two coolers: 18 & 9 width
One Unit, 18 lane, 7,2 meter wide-
Turkey -10,000TPD cooler
Narli Cement-12,000 TPD retrofit in 22 days
• Existing 7 years old German cooler limiting production!
• Casing, Kiln hood, Crusher, all internals & hydraulic station
Benefits:
• 1000 TPD Clinker production
increase with cooler upgrade
• No clinker fall through
• 20 Kcal/ Kg Cl fuel saving
• No pyro stoppage due to
cooler. 100% availability
• No Grate plates damage
from commissioning (+1 year
old cooler)
Zuari Cements Sitapuram- 3500 TPD
5 years running……18 days shutdown
Benefits:
• No grate plate is replaced
since commissioning.- 5
years
• No clinker fall through
• 28 Kcal/ Kg Cl fuel saving
• No pyro stoppage due to
cooler. 100% availability
• 300 TPD Clinker production
increase with cooler upgrade
• Lower input cooling air due
to STAFF controlled air flow.
Conventional old Cooler New Fons Cooler
 Zuari Cements- India cooler
performance
Parameter Unit Before After
Production TPD
3350 3650
Sec Air Temp Deg C 978 1203
Tertiary Air Temp Deg C 851 926
Cooling Air Nm3 air/ kg Cl 2.75 1.75
Clinker O/L Temp Deg C 113 120
Cooler exhaust Deg C
210 307
Temp
Cooler Loss kcal/kg Cl 145.8 120
Specific power of kW Hr/ t (fans+
4.8 4.2
Cooler drive)
 Century Cements- India, 2 years old
Cooler, Only Cooler upgrade
Parameter Unit Before After
Production TPD
2364 2895
Cooling Air Nm3 air/ kg Cl 1.72 1.8
Clinker outlet Temp Deg C 154 95
Specific Heat Kcal/ Kg Cl 806 759
1. 47 Kcal/ Kg Cl Sp heat reduction with cooler upgrade
alone.
2. Production increase achieved is 550 TPD. Preheater fan
rpm increased by 100 rpm only in the Calciner fan.
3. Cooler surrounding is absolutely dust free .
4. No more Snowman formation.
.
 Lafarge Holcim- ACC Cement
• Inspecting our coolers personally at
various installations, ACC Bargarh team
awarded a 3200 TPD cooler.
• For a record delivery of 5 months @CIF,
India. This was feasible due to our
modular concept
 Features
• Both for new coolers and retrofit, 2-3 weeks downtime!
• Zero fall through of clinker, reduced building height
• Low energy consumption (fuel and electrical)
• Up to 60 kCal/kg and 1-1.5 kWh/t savings
• Operating 1,95-2,33 kg_air/kg_clinker (1,5-1,8Nm3/kg)
• Design 2.56 kg_air/kg_clinker (1,98 Nm3/kg) (+10%)
• Guarantee: Clinker (65 deg+amb)
• : Standard cooler loss: 95kCal/kg
• : 3,7 kWh/t (fans); 0,3 kWh/t (hydr.)
• 0,005 euro/ton = 5/10 euro cent/ton (10% of others!)
• Grate Line: no more wear part. 5 years warranty!
 Other equipments from FTI

Primary Crusher Kiln shell Kiln tyres & support rollers

 Other equipments from FTI

Kiln HTD Kiln Graphite Seals Full Ball Mill or shell

 Thank you for your attention,
and thanks to 15th CII- Hyderabad
Kindly visit us at booth No. 20 to:
• get more info regarding,
• Know how we can serve your plant

Manager Indian Operation: Jayaram Sudhakar