Requirement From Cooler

Optimum recovery of the Sensible heat from

Kiln Discharge Clinker
Heat the Secondary air and Tertiary air
required for Fuel Combustion at Kiln &
Calciner firing
Rapid Cooling for clinker Quality improvements
Cooling the clinker to the Lowest
temperature, to help in transport, Storage
and Cement grinding
Availability
Less Power consumption
Less Maintenance cost

Optimum recovery of the Sensible heat

Heat Available
Tr )
0.18
6

Sh = A

+ B54

= 0.262

= 1.0
Wm * 0.262
Sh
* 1400
( Td
0
=
Kcal / Kg Clinker
367
* 1400
T
*10-6

Kcal / Kg

The sensible heat in cooling air 13 Kcal/kg

clinker
Total Heat Available = 380 Kcal (clinker temp =1400
o
C)
So Cooler has to designed to Recover all the Heat
The Percentage of recover is called the
Percentage of Cooler Efficiency

Cooler Efficiency
Cooler Efficiency can be divide in to two Group
Internal thermal efficiency
External thermal efficiency

Internal Thermal Efficiency is Using the

Recovered heat in Burning process

Secondary Air heating in Primary Firing

Tertiary Air heating in Calciner Firing

External Thermal Efficiency is Using the

Recovered heat for Other process

Rawmill, Coal Mill & Cement mill Drying

Heating & Power Generation

Internal thermal efficiency

=AB
A

X 100

= 380 124
380

X 100

= 67 %

A = Heat Available in Cooler

Heat content in Kg Clinker
Heat content in Cooling air
Kcal

- 367 Kcal
-

13

B = Loss from cooler per Kg clinker

- 124 Kcal

Loss in Vent air per kg clinker

95 Kcal

Loss in exit clinker per kg clinker 23 Kcal

Loss by radiation per kg clinker
-6
External
Kcal thermal efficiency is depends on the

utilization of vent air heat will vary plant to plant

Secondary air & Tertiary air utilization

Secondary air & Tertiary air Rate
(Combustion air + Excess air) (Primary air + False
air)

Combustion Air Required

1.411 Kg air X780

Sp. heat Kcal/ kg Clinker
--------------------------------------------- X 7 % Excess air
1000 Kcal

= 1.18 kg air /1.29 = 0.9 Nm3/Kg

Clinker

For combustion of 1000 Kcal minimum air

required
Oil firing
=1.420 Kg air
Natural Gas
= 1.439 Kg air
Standard Coal = 1.411 Kg air
Lignite Coal
= 1.420 Kg air
anthracites coal = 1.428 Kg air

Secondary air & Tertiary air utilization

Primary air consumption
15-20 % of combustion air Old burner
6 % of combustion air New Generation
burner
Secondary air can be in the range of 0.9 kg to
1.1 Kg
Heat recovery in cooler is depends upon
The heat consumption per kg clinker
Clinker leaving temperature from kiln
The qty of Primary air
Granulometric of the clinker
Vent air utilization
Using Less Cooling air with more recovery of
heat will improve the Cooler efficiency

Speed of Clinker Cooling

Rapid cooling prevents growth of crystals and
its size
Rapid Cooling, solidify the clinker in to glass
state
Tricalcium silicate (C3 S) and Magnesium oxide
(Mgo) will give Good Cement Strength
Large Mgo Crystal , further reduce the cement
strength
Rapid Cooling Improve C3S and reduce C2S leads
to
Easy grindablity
Lower energy consumption
Improve hydration and cement Strength

Development of Coolers Focus to

Minimum air for cooling
More heat recovery from less air
Fast cooling at Kiln inlet
Less wear and Protection of Grate plate for high
temp
Reduce the Power consumption
Reduce the Maintenance cost
Increase the Cooler Availability
Easy maintenance
Flexibility controls for easy operation

Rotary Clinker Cooler

Period

:- 1890 1930 Present Population

Capacity :- 2000 4500 TPD

Efficiency

:- 5 %

:- 50 60 %

Specific Cooling Air :- 0.8 1.0 Nm3 / Kg Clinker

Over all Heat Loss 140 Kcal / Kg Clinker
Power Consumption :- 1- 1.5 Kwh / Ton Clinker

B
A

A Clinker exit 1200 - 1400 Max Heat Value 370

Kcal
B Secondary Air 450 -700 o C Heat Value 233
Kcal
C Clinker Exit 200 300 o C Heat Value 60
Kcal
D Radiation Loss 80 Kcal

C
D

Planetary Clinker Cooler

Period

:- 1930 1980

Present Population

Capacity :- 2000 4000 TPD

Efficiency

:- 10 %

:- 60 68 %

Specific Cooling Air :- 0.3 1.0 Nm3 / Kg Clinker

Over all Heat Loss 140 Kcal / Kg Clinker
Power Consumption :- 1- 1.5 Kwh / Ton Clinker

B Secondary Air 800 -850 o C

B Kcal
A

A Clinker exit 1100 - 1350

Kcal

Heat Value 270

Max Heat Value 370

C Clinker Exit 150 200 o C

Kcal
C
D Radiation Loss 70
D

Heat Value 60

Grate Cooler
Period

:- 1940 -

Present Population

Capacity :- 700 10,000 TPD

Efficiency

:- 85 %

:- 60 75 %

Specific Cooling Air :- 1.6 2.6 Nm3 / Kg Clinker

Over all Heat Loss

:- 115 Kcal / Kg Clinker

Power Consumption :- 4.5 Kwh / Ton Clinker

A Clinker exit 1300 - 1400 Max Heat Value 370

Kcal
B Secondary Air 900 -1100 o C
B
A

C Clinker Exit 70 120 o C

D Vent air 250 280

Heat Value 20 Kcal

Heat Value 90 Kcal

E Radiation Loss 5
Kcal
E

Ist Generation Grate Cooler

Grate Inclination 10o
High Clinker Bed is not Possible 400 mm ht

Large Air chamber

Poor air distribution through grate

Un sealed air chamber because of in built drag chain

Not possible to distribute the air to required area

Platform or Water Cooled chute at inlet

Snowmen Formation and un uniform clinker distribution

Simple hole system in Grate plate

Enlarge due to wear and least resistance for air flow

Common air supply for all grate plate in each chamber

Poor air distribution according to clinker particle size

IInd Generation Grate Cooler

Grate Inclination 3-5

High Clinker Bed is not Possible 500 mm ht

Optimized air chamber length according to requirement

Slight improvement in air distribution through grate

Improved sealing by introduction of hopper and flap gate

Improvement in air distribution with different location

Dead grate and reduce the width at inlet

Improved the clinker distribution

Simple hole system in Grate plate

Enlarge due to wear and least resistance for air flow

Common air supply for all grate plate in each chamber

Poor air distribution according to clinker particle size

Conventional Grate Plate

Wedge shape Hole is provided
Hole enlarge by wear and air velocity reduce
All Grate plate is connected in Common Air
chamber leads to Uneven air flow based on
resistance by clinker particles
Chance of Hole plugging or Grate ridings
Air leakages through Side and in front of the
plate
Pressure drop 25 to 50 mm WC

IInd Generation Grate Cooler

Material size segregation at kiln discharge is affect the
Cooler Efficiency by Conventional Grate and common air
distribution system

Airflow is unevenly distributed across the cooler due to

changes in clinker granulometry
More air flow through Coarse side because of less
resistance
Less air flow through Fine particle side
These variable effects result in cooler inefficiencies.

Important of Grate Resistance

The Cooling air will always take the path of least
resistance
It make uneven air distribution and cause
formation of red river
To Over come this the air should passes through
a resistance before going to clinker bed
Resistance is the cumulative of pressure drop by
Clinker bed depth

Distribution of Coarse and fine particle

Pressure drop over the grate plate

To Increase the resistance, resistance type grate

plate has Developed

Resistance Grate Plate

Different shape resistance grate has
developed by different supplier
Air is passes through narrow slots instead of
hole
The air velocity and direction of slot is such
that it will eliminate the grate riddling or
Plugging
Higher resistance and pressure drop than
conventional grate 150 200 mm WC

Influence of the Grate Resistance

Uniform air distribution is achieved only by grate
resistance and not by clinker bed

Coars
e

CR

GR

FR

Fine
s

Grate

VC
Effect of
Grate
Resistanc

VF
Air

CR Coarse Clinker Bed

Resistance
FR Fine Clinker Bed
Resistance
G Grate Resistance
R

Vc Air Volume Coarse side

Vf Air Volume Coarse side
Air
Distribution

Vc

CR +GR

VF
FR +
GR
V
c
= 1 If GR > CR , FR
VF

Influence of the Grate Resistance

CR Coarse Clinker Bed Resistance - 75 mm WC
FR Fine Clinker Bed Resistance
mm
G WC
Grate Resistance
R

- 175
-

50 mm

Resistance Ratio (75+50) /(175+50) = 0 . 50

If we Increase the Grate Resistance to 250 mm
WC
Resistance Ratio (75+250) /(175+250) = 0 .
74
Theoretical Resistance ratio required is One,
But practically it is not possible

IIIrd Generation Grate Cooler

For uniform air distribution Resistance Grate plate with
Direct aeration system has developed
Air is supplied to a Group of Grate plate through separate
duct
That Group of Grate plate is supported in a air beam

Air requirement can be adjusted to individual group

So Uniform Air distribution is possible and uniform cooling
is achieved

Air Beam Technology

Fine Side

Coarse side
Resistance Grate
Plate

Air Entry

Group of Grate plate is

supported in a fixed or
Movable air beam
Air is supplied to Grate
plate through separate
duct and air beam
Air can be throttled by
valve to individual group

Air Entry

IKN Jet Plate

IKN is only developed the term resistance grate
first
Longer air chamber, resulting high pressure drop
S shape slot inclined towards the direction of
transport
Cool the plates Surface and bottom layer of
Clinker

Convey the fine fraction to top surface

only
It has
2-3 %the
open
area compared
Re entrain
air grate
for repeated
contact to to 8
clinker
to 12
% in conventional grate

This pattern is followed for the entire cooler

length

IKN Grate Plate

Hinge

Cooling Rib

Air Slot

Through Rod

Seal
Grate Beam
T-Bolt

Lock
Stop Nut

V = 1 m/sec

Vorf = 40m/sec

Mulden & CFG Grate Plate

The air slots are provided by side ways to avoid
dust fall through
The Pocket or Trough are filled with static layer of
clinker
Reduce the Surface wear

Give resistance to air flow

Always keep the bottom surface by Cool

Different pattern with same concept followed for

direct aerated Grate and Chamber aerated Grate
and Stationary Grate
KHD developed Stepped grate plate and Omega
Grate plates
Polysius developed Jet - ring and Jet - Stream
Grate plates

Mulden & CFG Grate Plate

FLS (CFG) Grate Plate

Cladius Peters Trough Grate Plate

Resistance Grate Plate

Effect of Grate Resistance on Air Distribution
Resistance
Grate

P2
X

P1

P1 Pressure drop in
Conventional
P2 Pressure drop in
Resistance
V
Maximum Velocity
Max

Conventiona
X Clinker Pressure Drop
l Grate

V1,2 Operating Velocity

V1,2 V2 max

V1 max

m / sec

If reduce Bed pressure drop = 0

The Velocity increase in conventional grate is 300 %
In Resistance grate is 30 %

Fixed Inlet Grate

The Worst affected area of cooler is inlet well
below the kiln discharge
Also High potential for gaining the heat from
discharged clinker
So all the supplier Develop a Fixed inlet Grate
Clinker Inlet Distribution System (KIDS)

- IKN

Controlled Impact System (CIS) - FLS -Fuller

High Efficiency Module (HEM) Claudius Peters
Air Beam technology and Resistance Grate plates
are used
High Bed and more heat recupation
Protection of Grate plate from wear and
temperature by Static Clinker bed

Fixed Inlet Grate

Objective of Fixed inlet grate is to create a

homogeneous clinker bed of uniform resistance
against the passage of air.
5 to 6 Rows of Fixed grates(3
meter) are fixed in a step
manner and form a 15 Deg
Slope
Because of rigidity withstand
high Impact and Temperature
Material Slide naturally or by Air
blaster

Grate Loading
Grate Loading has increased by direct aeration
system with Resistance type Grate plate

Conventional Cooler 25 40 T/m2 .d

Modern Cooler 60 - 70 T/m2.d

For 70 m2 Grate area

Capacity conventional Cooler 2800 - 3200

TPD

Capacity Modern Cooler 4800 - 5200 TPD

Air Loading per M2 grate area

Conventional Cooler -Air density 0.90

Nm3/m2.Sec

Modern Cooler Air loading 1.5 Nm3/m2.Sec

Modern Cooler Occupies less space

Grate Loading
Sec
.
m
2

3
m/
2 .Sec
N
3
/m
1.55
m
N
=
.35
Air
2 .Sec
1
=
3
r
m
i
2 .d
A
m/
N
m
/
5
2
d
1.1
=
60 t 3 t /m .
r
i
A
5
2 .d
c
/m
3 /m2 .Se
45 t
09 Nm
.
0
=
r
Ai
2 .d
m
35 t /

Cooler Bed Thickness

We can maintain high Bed Thickness by Direct
aeration system with Resistance type Grate plate

Conventional Cooler 450-500 mm

Modern Cooler 700 - 800 mm

Secondary air temperature

Conventional Cooler 800

Modern Cooler 1100

Air loading at Cooler Inlet

Conventional Cooler 100 kg/min/m2

Modern Cooler 200 Kg/min/m2

Air Pressure at Cooler Inlet

Conventional Cooler 400 500 mm WC

Modern Cooler 600 750 mm WC

Bed Thickness

Modern Cooler Fully Static Grate Plate

Requirement of New Development
high-performance
compact in size
Low-wear
Flexible during operation
Favorable price
Easy to maintain
To Achieve, 2 primary functions of cooler has
Separated
Cool the Clinker by Grate plate
Convey the Clinker by travel bars
FLS Fuller - Cross Bar Cooler

Krupp Polysius -Polytrack Cooler

SF Cross Bar Cooler

To Cool the Clinker
Stationary Grid
Having a self-regulated supply of cooling air
To Convey the Clinker
Simple, Cross Bar Conveying System
Separate and independent from grate line

Clinker Conveying Mechanism

Plan View
Movable Cross Bar
Stationary Cross Bar

Stationary Plates

Sealing Profile

Movable Retainer Bracket

Stationary Retainer Bracket

FLOW OF CLINKER

Cross Bar Cooler

Cross-Sectional View
Movable Cross Bar
Movable Retainer Bracket

Sealing
Profiles

Movable Frame Bearing

Stationary Retainer Bracket

Drive Plate

Stationary Plates

Movable Frame Assembly

Clinker Conveying Mechanism

Elevation View
Movable Retainer Bracket
Movable Cross Bar

Stationary Retainer Bracket

Stationary Cross Bar

Dead Clinker Layer

Stationary Air Grid

FLOW OF CLINKER

Stationary Air Grid

No Moving Grate Plates
No conveying function and is protected by layer of
clinker
No interface between air plates and refractory
No side seals
No need to remove refractory to replace a
Plate

Grate

RESULT
Extended Grate Life & Less Maintenance

Stationary Air Grid

No clinker fall-through
No Spillage hopper & Flap valves
No under-grate clinker transport system
No internal piping
No inefficient sealing air required to prevent
spillage
RESULT
Less Maintenance
Lower Head Room Requirements
Kiln & Preheater Height will be reduced

Independent Clinker Conveying

Wear Components Have No Effect on Cooling
Efficiency
Static Clinker Layer above Cross Bars Protects Air
Distribution Plates from Heat & Wear
Cross-Bars Effectively Convey, Mix, and Shear Clinker
to Maximize Heat Exchange
Quick and Simple Replacement of Wear Parts
Hydraulic drive for efficient drive
Variable Speed for each Module line to Control Red
river

Clinker Conveying Mechanism

Air Distribution Plates With Mechanical Flow

Regulators
MFR acts as a variable orifice control the cooling
air automatically to compensate the changes in
the clinker layer such as temperature, bed depth,
and granularity
Constant Air Flow through the
Clinker Bed, Independent of Process
Conditions
MFR Results in Reduced Electrical
Power
Optimum Air Distribution throughout
the Lifetime of the Cooler
Supply required air to each plate
according to Clinker bed Resistance
Operate by principle of Differential
pressure between chamber and
Grate plate bottom

Air Distribution Plates With Mechanical Flow

Regulators

Mechanical Flow Regulators

LOW BED
RESISTANCE

HIGH BED
RESISTANCE

LOWER

HIGHER

VALVE DP

VALVE DP

C O N S T A N T

A I R

F L O W

Function of Mechanical Flow Regulators

POLYTRACK Cooler
The POLYTRACK - a unique combination of
Horizontally positioned static aeration
floor
Over floor transporting system
Ideal transverse distribution of the clinker
extremely low construction height

Air Distribution Systems

The air is distributed via the labyrinth construction of
the static aeration Grate
The Grates are located between the transport
tracks
Large boxes integrated into the aeration
elements are permanently filled with clinker
This provide autogenously wear protection
No Dust Fall through Grate

Transport tracks
Transport tracks are arranged in line with the
direction of clinker conveyance
The rows of transport tracks are positioned a certain
distance from each other and the aeration elements
is located between them
The number of transport track rows is determined
by
the
required
thethe
cooler
Every
row of width
tracksof
runs
entire length of the cooler
To convey the clinker, the transport tracks move
forward together and then move backward individually

Advantages of New Generation Cooler

Operational
Advantages
Stable kiln & cooler performance due to less dust
circulation and no blowing of cooling air

Less red river tendency due to the Controlled Flow Grate syst

Control red river by varying the speed of Individual line of mo

Very Good Heat recuperation and high secondary air
temperature 1100 o C Will give uniform Flame
Less snowman tendency
No Fall through of dust
Reduction in clinker temperature 80-90 oC

Benefits
Reduction in cooler losses -30-40 Kcal/kg

Reduction in power consumption from 4.5 Kwh to 3.5 Kwh /T

Low maintenance costs due to minimum wear on grate
plates and movable parts

Other Benefits

Small overall dimensions due to high specific grate load

70 t/m2 .Day than 40 t/m2.Day for conventional
cooler
No Spillage hopper and Bottom dust handling
equipments
Less Head room and reduce the Kiln pier and Preheater
height by 3 Meter
Reduction in cooling and vent volumes by 30 %
and leads to smaller fans
Because of Lower exit clinker temperature the
Further conveying equipment perform well
Because of Lower exit clinker temperature the
Cement Grinding mill perform well

Clinker Cooling Efficiency in Various Grate Cooler

Secondary Air Required 0.866 Nm3 /Kg
Heat Recovery

Cooling

1500
1300

Low Efficiency Cooler

1200

Good Conventional Cooler

Air beam Technology Cooler

1100
1000

Fully Static Cooler

900
800
700
600
500
400
300

675 o C
560 o C
475 o C
390 o C

200
100

Cooling air Nm3 /Kg Clinker

Clinker Temperatureo C

1400

Cooler Comparison
Rotary
Cooler

Planetary Grate
Cooler
Cooler

Air beam
Grate
Cooler

Stationar
y Grid
Cooler

Efficiency %

55-60

60-70

65-70

70-75 %

75-80%

Sec.Air Temp oC

440700

700-850

800950

950-1100

11001220

NA

NA

700750

750-900

900-1000

NA

NA

250275

225-250

200-225

150300

120 - 200

100120

80-100

60-80

Radiation Loss Kcal/Kg

50-80

30 40

56

45

45

Cooler air volume

Nm3/Kg

1.2-1.5

1-1.1

23

1.7-1.8

1.5-1.7

Air venting Nm3/kg

0.3

Nil

0.8-1.2

1.5-1.6

0.75-0.95

0.6 - 1.3

5-7

56

142

130

100

Tertiary Air Temp

Vent air Temp

Clinker exit Temp

Specific power Kwh /

ton
Heat Loss in Kcal /kg

160

3.5 4.5
85