CLINKER COOLING

Clinker cooling

The cooling of the clinker influences its structure, the mineralogical composition, as well as the

Grindability, and consequently the quality of the resulting cement.

Clinker cooling is necessary because:

• Hot clinker is difficult to convey

• Hot clinker has a negative effect on the grinding Process.

• The reclaimed heat content of the hot clinker of about 200 kcal/kg is an important factor lowering

the production cost.

• Proper cooling improves the quality of the cement.

Speed of clinker cooling

The speed of clinker cooling influences the ratio between the content of crystalline and liquid phases in

the clinker. During slow cooling, crystals of almost all clinker components are formed, whereas fast

cooling hampers formation of crystals, causing part of the liquid phase to solidify as glass. Moreover,

fast cooling prevents growth of crystals. The proportion of liquid phase in clinkers from rotary kilns is in

the range from 20- 25 %.

Fast clinker cooling influences especially the behavior of the magnesium oxide, and therefore also the

soundness of the resulting cement. The faster the clinker cooling the smaller the periclase crystals

(magnesium oxide) which emerge by crystallization of the liquid phase

Soundness and clinker cooling

The soundness of the hardening Portland cement depends on the size of the periclase crystals. The

hydration of larger periclase crystals, which is connected with a simultaneous increase in volume, is

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slower than the hydration of the clinker forming minerals; this impairs the soundness of the hardening

cement. The maximum size of the periclase crystals which hardly impair the cement is about 5-8

microns. Slow clinker cooling can produce periclase crystals about 60 microns large. It was found that 4

% periclase crystals in the cement, up to 5 micron in size, show the same rate of expansion in the auto-

clave test, than 1 % periclase crystals, which are 30- 60 microns large.

The American ASTM Standards on Cement [261], limit the expansion of Portland cement (Types I-V) in

the autoclave test to 0.8 %. Slowly cooled clinker with an MgO-content of about 2.5 %, mostly fails the

autoclave expansion test. Magnesium oxide solidified to glass, does not impair the soundness of

cement.

Rapid clinker cooling allows for a higher MgO-content in the clinker, whereas slowly cooled clinker

should have a rather low MgO-content. The cooling rate of clinker with up to 1 % MgO is not so decisive

for the soundness than MgO-contents between 1 % and the upper limit, which in cement standards is

mostly 5 %, in the British standards 4 %.

Slow clinker cooling promotes the growth of clinker minerals. The size of alite crystals does not only

influence the clinker Grindability (large crystals need additional energy for comminution), but also

affects hydration and cement strength. Alite crystals which by proper burning and rapid cooling are kept

small result in higher cement strengths [265]. Of two cements with identical chemical composition, the

one with smaller alite crystals (15 microns), was stronger; its 28-day compressive strength was 391

kg/cm2, whereas the compressive strength test of cement with 40 micron diameter crystals was

only 293 kg/cm 2 [262].

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Cooling and resistance to chemical attack

Rapid clinker cooling also increases the sulfate resistance (sodium and magnesium sulfate) of the

cement. This is explained by the fact that the C3A-content, which is related to the resistance of Portland

cement to attack by sulfate solutions, is mainly present in aglassy state, when cooled rapidly; in this

form the C3A is much less susceptible to attack by sodium or magnesium sulfate.

Fig. 21.1 shows the expansion of two mortar rods, made from the same clinker containing 11 % C3A, and

stored in a 5 % solution of magnesium sulfate. In one case- applying slowly cooling- the C3A crystallized

completely, whereas in the other case the clinker was cooled rapidly [263]. The curves show the definite

advantage of rapid clinker cooling.

Cooling and Grindability of the clinker

By means of two diagrams Fig. 21.2 shows a Grindability comparison of rapidly and slowly cooled

clinker. Clinker which was (slowly) cooled in a rotary cooler shows a higher specific power requirement

for grinding in kWh/t, than clinker which was rapidly cooled in a Fuller grate clinker cooler [264]. A

higher proportion of liquid phase as well as smaller crystals of clinker minerals cause the grinding of this

clinker to be easier than grinding of slowly cooled clinker.

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These observations concerning the necessity of rapid clinker cooling and the ensuing preheating of air

were recently decisive factors for the development of clinker coolers.

Clinker coolers

To form an opinion on clinker coolers, the following criteria should be considered:

a) The thermal efficiency of a cooler designates the ratio of the heat reclaimed from the hot

clinker, and utilized in the burning process, to the total heat content of the clinker leaving the

kiln. The thermal efficiency (E) is expressed as:

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The thermal efficiency of rotary kiln clinker coolers of all types of design is within the range of 40 to

more than 80%.

b) Another criterion for judging the cooler efficiency is the temperature difference between the

hot clinker entering the cooler and the hot secondary air leaving the Furthermore, the best

cooler is the particular cooler which, because of its general efficiency, supplies the

maximum amount of heat into the rotary kiln with the secondary air.

c) The degree of clinker cooling is designated as the temperature of the clinker leaving the cooler

this temperature differs in the various types of coolers from 50 to 300o C.

d) The specific energy requirement of rotary and satellite coolers is lower than that of all other

clinker coolers.

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e) The cooling air volume of rotary, satellite and shaft coolers is limited to the air volume,

necessary for maintaining the combustion process in the rotary However, the clinker leaving

these coolers has higher temperatures.

f) The lower temperature of the clinker coming from the grate cooler is a result of the higher air

volume used for clinker cooling. The hot surplus air is partially utilized for drying and partially

dis- charged into the atmosphere; this necessitates dust collection which causes additional

costs.

These influencing factors hinder the evaluation of clinker coolers, since frequently an advantage on the

one hand must be paid by losses on the other.

To calculate the temperature of the secondary air the following empirical formula can be used:

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