ADVANCEMENTS IN CLINKER COOLER

Satellite Cooler tubes

 Internals in satellite coolers

Inlet section : refractory brick lining of step

design

Middle section : breakers, lifters and scoops

with refractory or steel plate
liners below

Outlet section : lifters and scoops without

lining below

Dam rings : to improve retention time of

clinker
 Conventional grate coolers

* Based on aeration of undergrate compartment

- Segregation of clinker discharged from kiln.

- air flow high

* on downstream side of compartment
where clinker temperature is low
* on the sides where bed is thin
* opposite to load side of kiln where clinker
is coarse
 Separation effects due to kiln rotation

Coarse clinker side, low pressure

drop

Fine clinker side, high pressure drop

Coarse Fine
clinker clinker
Clinker Uneven velocity
Segregation profile across
happens in the the width of the
kiln and continues cooler
in the cooler

Conventional Coolers
 Air Flow - Resistance to flow

- Air Flow at any location depends on

* grate resistance + clinker bed resistance

- Clinker bed resistance depends on

* Clinker temperature
* Bed thickness
* Clinker size

- Air takes the path of least resistance.

 1st Generation grate Coolers

* Low clinker bed depth due to grate inclination upto 10

degrees
* Poor air distribution due to excessively large air chambers
* High requirement of cooling air for overcoming poor
distribution of air and achieving satisfactory cooling of all
clinker.
 2nd Generation Grate Coolers

-Improvement in Air Distribution By

* Optimisation of chamber sub division

* Location of drag chain outside cooler

- Increase Heat Recovery , Grate Plate Life and

reduced cooling air due to higher bed thickness at
inlet achieved by reduction in grate width and slope.
Effect of grate resistance on air distribution
 Modern coolers adopted elevated resistance grate plates

Effect of grate resistance on air distribution

 Modern grate coolers

*Air beam coolers

Direct aeration of grate plates
mounted on aerated hollow beams.
*Fully static grate coolers with separate
reciprocating mechanical elements for
conveying and distribution of clinker
over the grate.
 Coolers of different machinery suppliers

• CIS-CFG-RFT cooler of FLS

• IKN Pendulum cooler
• Pyrostep cooler of KHD Humboldt Wedag
• Repol- RS cooler of Krupp Polysius
• BMH Claudius Peters cooler with HE module and
Compact Swing Support (CSS) system
• ETA cooler of Claudius Peters
• SF cross bar cooler of FLS
• Polytrack cooler of Polysius
• Pyrofloor of KHD
 Air beam systems

* Static inlet grate of 2.5 - 3.0 m length

- offers rigid support against of impart of
clinker and reduces maintenance costs

* Subsequent moving and stationary rows

- compartment - aeration type
- direct aeration type
- combination
contd..
Contd.

* Air supply with pulsating action to static

inlet grate
- short term increase in pressure and
volume of air.
- loosens clinker and achieves uniform
distribution.
- sudden cooling
- effected by directing flow from one air
beam to another or alternately to left and
right halves of each air beam.
 EASILY REPLACEABLE,
ADJUSTABLE PUSHER FACE

MOVEABLE FIRST ROW LOW SEALING AIR

Moveable grate air supply -Side view

Air beam technology

 Fixed Plate Movable Plate

Sliding Compensator

Direct aeration of fixed and moveable rows

 Advantages of Direct Aeration
1. Reduced heat consumption of kiln
2. Low preheater fan and cooler fans power
consumption
3. Reduced cooler vent air for dedusting
4. Higher specific grate loading and retrofit
possibility - potential for production increase
5. Extended grate plate life, reduced grate
riddlings - Reduced maintenance and high
operational reliability
6. Stable flame and positive effect on kiln
operation
 FLS- CFG COOLER

Fuller’s CFG plates

Long-life, flexible air hose

connection
Simple under grate duct
Work arrangement utilises
Beams as ducts and leaves
Room for maintenance access
Cooler temperatures in the Low sealing Reduced maintenance
undergrate compartment air requirements Cost for the dust valves
prevent support beam distortion And dust handling system
 1 Ducting
2 Manifold
3 Distribution lines
4 Control valves
5 Flexible connectors
6 Moveable frame
7 Grate supports

Elements of CFG system

 Controlled Impact System (CIS)

- 6-8 stationary rows forming a 15o

sloping inlet section
- slope allows layer of clinker to form in
impact zone
- static layer causes sliding of clinker
upon clinker throughout the zone
- grate wear eliminated
- cooler availability improved
 Clinker flow

Stationary inlet section

 Air Blasters

CIS

Controlled Impact System (CIS)

 Reduced Fall Through (RFT) Plates

* used in after cooling zone following CFG section

* grate similar to CFG system

* Life time more than twice the standard plate

* reduced material spillage

* Improved air distribution

* chamber aeration
 IKN PENDULUM COOLER

Features of Pendulum Cooler

- stationary clinker inlet distribution

system (KIDS)
- partial fluidisation with horizontal jets
(Coanda effect)
- blade technology
- wearless suspension of mobile frames
 IKN- KIDS

* 6 – 8 stationary and stepped enclosed air beams

* air beams aerated by individual ducts
* left and right side division of each air beam
* pulsating air flow with extremely narrow slots
for even air distribution
* refractory side dams to collect & aerate segregated
clinker from kiln discharge
* air blasters to avoid snowman formation
 IKN grate plates - COANDA Effect

Sharp jets of air through narrow slots in

the direction of clinker conveying. The
high dynamic pressure sucks the jets
close to the surface of the grate plates
IKN grate plate with COANDA EFFECT
 Properties of IKN grate plates

- equal as there is the same air velocity in each opening

- numerous in order to finely distribute the air within the grate
elements
- narrow to create resistance and high jet velocities
- transverse with respect to the direction of clinker transport to fully
aerate the solids passed
- inclined towards the direction of transport in order to
* cool the plate’s surface and the bottom layer of clinker
* convey the fine clinker fraction usually causing friction and wear
* reentrain air from the clinker bed for repeated air to clinker
contact
- curved against the direction of gravity to prevent the passage of
riddlings enabling the grate beams to serve as air compartments
called ‘air beams’.
 Blade

Blade technology
 Pendulum suspension

• In standard cooler design with roller support,

mobile frame starts sinking during operation due
to wear of roller
• The bottom of mobile row touches top of
consecutive fixed row and both wear out.
• IKN design of self centering pendulum
suspension of the mobile frame evolved to avoid
the above.
Pendulum suspension
Movable frame supported on spring straps
BMH CP COOLER WITH HIGH EFFICIENCY MODULE
AND COMPACT SWING SUPPORT SYSTEM

* HE module at inlet of cooler

* Compact Swing Support (CSS) system

* Anti riddling side plate system

* Slotted plates in complete grated area

* Controlled fine clinker aeration

 Fixed Plate Movable Plate

Sliding Compensator

Direct aeration of fixed and moveable rows

Compact Swing Support – CSS system
 PYROSTEP COOLER OF KHD- HW

Cooling Zones in Pyrostep cooler

Zone-I : Stationary stepped grate, 6 rows

Zone-II : Reciprocating grate section, 5 rows of
omega plates
Zone-III : Stationary step grate similar to Zone-I
Zone-IV : Reciprocating grate section similar to
zone-II
* In zone-I to IV, each row is individually supplied with
variable volume of cooling air
* zone V - chamber aeration
Zone I II III IV or V

Cooling zones in Pyrostep cooler

 IV

II
I III

Grate plates in different zones of Pyrostep cooler

 Aeration in Zone II
(Reciprocating grate section)

* Direct aeration to individual rows

* air supply to fixed rows through grate plate

supports formed as conduits

* air supply to moving rows through linear

sliding tube sealing
 Pulsators for aeration
Pulsators for aeration
Period 1 Period 2

Rows of Rows of Movable

stationary plates Fans with
plates Control
damper

Omega or
Stepped grate plates area Omega plates area standard
Stepped grate plates area
plates area
Air distribution pattern
KHD Stepped grate plates
KHD Omega plates for direct aeration
KHD Omega plates for chamber aeration
REPOL-RS COOLER OF KRUPP POLYSIUS

Inclined
Grate

Static
inclined
Grate

First and second generation coolers

 Aeration system of Repol-RS

* specifically directed allocation of air supply fans

* length-wise division of grate into aeration sections
* confining fan for each aeration section
* aeration of fixed rows through grate plate support
beams
* aeration of moving rows by wear free sliding seals
 Side strip

Middle strip

Side strip

Strip aeration of the static grate

Supply of cooling air to fixed rows
Sliding
Seal

Supply of cooling air to moveable rows

Krupp – Polysius jet - ring plate
Krupp – Polysius jet stream plate
 SF CROSS BAR COOLER OF FLS

* self regulating (active) mechanical air flow

control

* fixed and non-wearing grate line for air

distribution

* separate clinker conveying system

* modular design and construction

 Active air distribution

* air distribution plates characterised by low pressure

drop
* each grate plate equipped with mechanical flow
regular (MFR)
* amount of cooling air from undergrate chamber
into grate plate controlled by MFR
* constant airflow through clinker bed maintained,
independent of process conditions
* MFR opens/closes to compensate for increase /
decrease in clinker resistance
 MFR

Uniform Clinker Size Non - uniform Clinker Size

Self regulating mechanical air flow control

 Fixed non-wearing grate line

* no moving grate plates

* grate line is a grid supporting air distribution plates
* grate performs no conveying functions
* grate protected by a static layer of clinker
* no undergrate clinker transport system
* side casting and side seals avoided
* no sealing air requirement
 Static Grate

Cross Bar

Fixed, non wearing grate line

 Separate clinker conveying system

* reciprocating cross bars-stationary and

moveable fitted above stationary air distribution
system, convey clinker
* wear of cross bars does not affect cooler
efficiency due to separate conveying and air
distribution systems
* static clinker layer between air distribution plates
and cross bars
* easy replacement of cross bars
Fixed Bar

Movable Bar

Reciprocating cross bars

 Modular design

* fixed inlet module followed by standard modules

* standard module – 4 grate plates wide x 14
grate plates long
* modules set side by side and end to end
* modules can be pre-assembled
* modules installed end to end have movable
frames connected
* modules installed side to side do not have
movable frames connected- individual speed control
Standard 4 X 14 Module

Modular design
 Multi Movable SF Cooler

• stationary grate line

• air distribution plates with individual airflow
regulation
• patented sealing profiles
• no undergrate spillage
• modular construction
• separated conveying & cooling
mechanisms
• The MMC Cooler comes in cassettes, similar to the
modules on an SFC Cooler, minus the supporting
frame.
• Each cassette has two built-in drives and cross-bars
over the grate line.
• All of the cross-bars in the cassettes are movable,
which improves transport efficiency.
• And the drives can have individual stroke lengths and
speeds to meet any special challenge handling the
clinker bed.
Static Inlet High Efficiency Module
 Controllability of the ETA Cooler

Recuperation zone Cooling zone

Active Controllability of Clinker Bed

Static inlet section Efficient heat recuperation

Chamber Side Aeration Controlled zone cooling

Individual stroke length Flexible clinker retention time

 V clinker
Principle of Movement
Forward stroke
Fixed inlet

FR wall

V clinker

FR wall

F pressure Backward stroke

Fixed inlet

FR bulk solid
Vclinker
FR bulk solid
 Result of varying Stroke Length
Across the Grate Width

Low Layer
Height

High Layer
Height
Influencing the Clinker Distribution
 Autogenous wear and heat protection

93 % of the total grate surface is

protected by clinker

Clinker bed transport

Hardfaced wear protection

Fixed clinker Stroke
layer

The remaining is wear protected

Cooling Air by hardfacing
POLYTRACK COOLER OF POLYSIUS

• Stationary Aeration Floor

• High Efficient Transport System
• Horizontal Grate Arrangement
• No Clinker Fall Through
• Optimum Clinker Distribution over the
Width
• No Under Grate Clinker Transport
• Modular Component Design
Set up of POLYTRACK®
Modular design
Pre-Assembled POLYTRACK® Module
 Polytrack cooler
Static Aeration Floor Transporting System
 Aeration Element

individual aeration plates bolted onto static aeration floor supporting framework
 Intermediate Crusher Concept

Roller Crusher

POLYTRACK® Grate 1
POLYTRACK® Grate 2
 PYROFLOOR COOLER

 Active clinker distribution

 Self regulating aeration

 Low cooling air amount

 High thermal efficiency

 Reduced construction height

 Modular design
PYROFLOOR COOLER
 New Aeration Concept
• The cooler features a completely new developed
aeration concept to avoid the typical problems like
hot spots and air fountaining, which are occuring in
more conventional designs.

• By combining the Flow Regulators to each one

aeration cassette, the basic problem of clinker
cooling is solved.

• The non-uniform height and temperature distribution

of the clinker-bed can now be met with a precisely
balanced air supply to any spot of the grate without
the usual complicated ductwork and flaps.

• Flow regulators with different rated flows are placed

beneath the grate in order to provide a well tuned
aeration.
 PERFORMANCE OF AIR BEAM COOLERS

Thermal Efficiency : 72-77 %

Cooling Air Quantity : 1.5-1.9 Nm3/Kg Clinker

Thermal Energy Saving : 40-70 Kcal/kg Clinker

Grate Loading : 50 - 65 tpd/m2

 Heat recuperation in conventional
and modern coolers

Cooler Type Clinker Cooler Avg. Air

Temp.0C Loss Temp. 0C
Kcal/Kgcl
Low Efficiency Grate 675 155 840
Cooler
Good conventional Grate 560 125 930
Cooler

Cooler based on air beam 475 105 1000

technology

Cooler based on improved 390 85 1065

air beam technology/ full
static grate.
 Red River

- Narrow stream of uncooled red hot fine clinker flowing

down the cooler.

- Red river occurs due to uneven depth and size

segregation of clinker across the width of cooler resulting in :

* Diversion of cooling air through bed of

coarse clinker and less bed thickness.

* Fluidisation of fine clinker and air slide effect.

Red River in a Clinker Cooler
Typical course of a red river
 Remedial measures for Red River

• Reduction in cooler width at inlet to give deeper bed

and greater uniformity across width of cooler.

• Use of wedge plates with higher pusher face along

path of red river, to divert fine material and mix it
with other clinker.

• Use of air beam technology.

Refractory cover
SNOWMAN FORMATION
 REMEDIAL MEASURES FOR SNOWMAN FORMATION

• Installation of air blasters in back wall of the cooler

and on the sides as well as between the steps of
static inlet grates.

• Top surface refractory covering on either side of the

cooler should slope towards the centre of the cooler.

• Extra air input to the clinker drop zone.

• Pushing the burner pipe slightly into the kiln to create

a longer cooling zone in the kiln itself.

• Improved quality and process controls to avoid irregular

kiln feed chemistry and unstable operation of kiln.
Air blasters

Air Blasters
Air blasters above static grate line
Air blasters between steps of static grate