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The Purpose of A Cooler Is, Obviously To Cool The Clinker - This Is Important For A Several Reasons

The document discusses the purpose and functions of a clinker cooler. It cools clinker to prevent damage to equipment, minimize temperatures entering the clinker mill, reduce energy usage, and enhance cement performance. It defines various types of air used in the cooling process and discusses parameters that affect cooler performance like clinker properties and air flow. It also covers control loops used to maintain constant air flow, clinker bed height, and other variables.

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Zegera Mgendi
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© © All Rights Reserved
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Download as PPTX, PDF, TXT or read online on Scribd
132 views

The Purpose of A Cooler Is, Obviously To Cool The Clinker - This Is Important For A Several Reasons

The document discusses the purpose and functions of a clinker cooler. It cools clinker to prevent damage to equipment, minimize temperatures entering the clinker mill, reduce energy usage, and enhance cement performance. It defines various types of air used in the cooling process and discusses parameters that affect cooler performance like clinker properties and air flow. It also covers control loops used to maintain constant air flow, clinker bed height, and other variables.

Uploaded by

Zegera Mgendi
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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INTRODUCTION

The purpose of a cooler is , obviously to cool the clinker .

This is important for a several reasons –

a) From an engineering point of view , cooling is necessary to


prevent damage to clinker handling equipment such as
conveyors .
b) From both a process and chemical point of view, it is
beneficial to minimize clinker temp. as it enters the
clinker mill.

The clinker gets hot in the mill & excessive mill


temperatures are undesirable . It is clearly helpful as the
clinker is cool as it enters the mill.
C) From an environment and cost view of point –
The cooler reduces energy consumption by
extracting heat from the clinker ,enabling it to be used
to heat the raw materials .
D) From a cement performance view of point , faster
cooling of the clinker enhances silicate reactivity .
SOME IMPORTANT DEFINATIONS
COOLING AIR

PRIMARY AIR

SECONDARY AIR

TERTAIRY AIR

MIDDLE AIR

WASTE AIR

FALSE AIR

SPECIFIC AIR

SPECIFIC LOADA

RADIATION LOSSES
COOLING AIR
 Cooling air is the air which passes the clinker

thus being heated up while cooling the clinker. It

corresponds approximately to the combustion air

requirement, only grate coolers allow additional air

for better cooling.


PRIMARY AIR
Primary air is the air which is required for the proper

functioning of the burner. Ambient air insufflated by a


separate small fan plus the air from a pneumatic transport
system, amounting from <10% upto >30% of the air reqd.
to combust that fuel.
SECONDARY AIR
Secondary air is the hot air entering the rotary kiln via

clinker cooler. Its flow is determined by the combustion


of the burning zone fuel. While cooling the clinker it
reaches temperature of 600 to over 1000°C depending
on type and condition of the cooler.
TERTAIRY AIR
Tertiary air is that part of the combustion air which is

required for combusting the precalciner fuel. It is


extracted from kiln hood or cooler roof, and then taken
along a duct parallel to the kiln to the precalciner. IT
reaches temperatures near or equal to the level of the
secondary air.
MIDDLE AIR
Middle air is extracted from the cooler roof if drying of

process materials requires a temperature level which is


higher than the waste air. If the quantity is small upto
450°C can be expected at normal cooler operation.
WASTE AIR
Waste air (grate cooler only) is also called cooler exit air

or cooler excess air. The total cooling air flow from the
fans is normally higher than the flow required for
combustion. The extra air which has normally a
temperature of 200 to 300°C must be vented to ambient
via a dedusting system.
FALSE AIR
False air is cold air entering the system via kiln outlet

seal, burner opening, casing or clinker discharge. It


either dilutes secondary air thus reducing recuperated
heat or adds load to the waste system of grate coolers.
SPECIFIC AIR
Specific air volumes are air flows per kg of clinker

(m3/kg clinker,Nm3/kg clinker). Independent of the


kiln size, air flow of cooler systems can be directly
compared.
SPECIFIC LOADS
Specific loads express the relation of clinker

production to a characteristic dimension of the


cooler.
RADIATION LOSSES
Radiation losses from the cooler casing/shell are

particularly important for planetary coolers, where they


actively support the cooling of the clinker. Page C - 2 of
22
EFFICIENCY EXPRESS
Efficiency expresses the quality of heat transfer

from clinker to the air which is used for combustion


in the burning zone and precalciner firing.
FUNCTIONS OF CLINKER COOLER
QUENCHING OF CLINKER –
To control the expansive character of MgO by
stabilizing it in a glassy state .
RECUPERATES –
Heat from Clinker in secondary air resulting in
stable kilin operation & fuel economy .
COOLS the clinker to low temperature for easy
handling .
CONVEYS the clinker .
BREAKS - large chunks of clinker .
EFFECT OF COOLING
A CHEMICAL PROPERTIES
Slow Cooling -
a) MgO – Pericles crystals, instead of in glassy state.

b) C3A , C4AF – Remain in crystalline form .

C) C3S , BCeS – Less active and stable


B PHYSICAL PROPERTIES
Slow cooling

a) hydraulic activity – less

b) partial size – bigger

c) grinding energy – more

d) sulfate resistance - less

e) expansion – more

f) strengths – high early & low late strength.


PROCESS PARAMETERS AFFECTING GRATE COOLER PERFORMANCE -
GRANULOMETRY OF CLINKER .

TEMP. OF CLINKER AT COOLER INLET .

CLINKER DISTRIBUTION ON GRATE .

FLOW OF COOLING AIR .

COOLING AIR DISTRIBUTION .

TEMP OF COOLING AIR .


GRATE SPEED / RETENTION TIME OF CLINKER .

CLINKER BED HEIGHT .

UNDERGRATE PRESSURE
CONTROL LOOPS FOR GRATE COOLER
I) CONSTANT COOLING AIR FLOW –

Total cooling air to recuperation chambers remain


constant .

FLOW IS HELD CONSTANT BY CONTROLLING INLET


VANES .
II) CONSTANT CLINKER BED HEIGHT

UNDERGRATE PRESSURE IS A MEASURE OF


CLINKER BED HEIGHT .

CLINKER BED HEIGHT IS CONTROLLED BY


GRATE SPEED .
III) CONSTANT HOOD PRESSURE HELPS IN :

STABLE BURNING ZONE

MAINTAINS REQUIRED AIR FLOW FROM COOLER TO

KILN .

CONSTANT KILN HOOD IS MAINTAINED


ADJUSTING COOLER , INDUCED DRAUGHT FAN
DAMPER / SPEED
IV) CONSTANT GRATE SPEED RATIO

PREVENTS ANY CLINKER ACCUMULATION

ON INTERMEDIATE GRATE.
CLINKER INLET TEMP = 1400C
CLINKER TEMP. AMBIENT TEMP.= 20 C

COOLING AIR
QUANTITY
Nm3/ kg clinker
KW H/T Specific Energy
RECUPERATION DOCCUMENT IN
INITIAL PART OF COOLER

COOLING DOMINENT IN LATER PART OF


COOLER
COOLER OPTIMISATION
 SECONDARY / TERTIARY AIR FLOW
AND TEMPERATURE
MAXIMIZE

 CLINKER OUTLET TEMPERATURE


MINIMIZE
COOLER VENT AIR FLOW
AND TEMPERATURE
MINIMIZE
Cooler efficiency
SENSIBLE HEAT = M * Cp * T

M - MASS FLOW RATE


Cp - SPECIFIC HEAT
T- TEMPERATURE DIFFERENCE

I COOLING EFFICIENCY =

Sensible heat of clinker  sensible heat of clinker out of


int. cooler cooler
sensible heat of clinker into cooler
RECUPERATION EFFICIENCY =
 SENSIBLE HEAT OF SECTION AIR

SENIBLE HEAT OF SENSIBLE HEAT OF


CLINKER INTO  TOTAL COOLING
COOLER AIR
RESIDENCE TIME IN COOLER
60 ahy
T=
R
WHERE –
a = area of which the cooler grate surface
h = bed depth
y = clinker density
R= kiln output kg per hr.

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