DESIGN CRITERIA OF COOLER

Section Parameter
Cooler width, m 0.6 * Kiln diameter
Cooler loading, tpd /m2 55 – 65
Cooling air quantity, 1.85 – 1.90 ;
Nm3/kg > 2.3 air quantity,
recuperation efficiency
of cooler remains flat,
i.e. further clinker
cooling not possible
Vent air quantity, 1.0 – 1.2
Nm3/kg
DESIGN CRITERIA OF COOLER

Section Parameter
Kiln hood gas velocity (m/sec) 3.5 to 4.0, < 5
TA take off velocity (m/sec) 6 to 7
Cooler off center
w.r.f to Kiln center (mm)
< 1500 tpd clinker production 300
1500 to 2500 tpd production 400 to 450
> 2500 tpd production 550 to 600
COOLER OPERATION
A. Cooler Efficiency
= Heat Recovered x 100%
Heat Input

= Heat with SA + TA + Coal Mill Air x 100%

Heat with (Clinker + Cooling air)

Difficulty in determination of efficiency

• Secondary air temperature
• Secondary air quantity
• Temperature of clinker entry to cooler
COOLER OPERATION

OR
B. Cooler Efficiency
= Heat Input – Heat Loss x 100
Heat Input

Heat loss = heat with clinker +

heat with cooler vent air

Here again temperature of clinker entry to

cooler is difficult to determine.
COOLER EFFICIENCY DEPEND ON

1. Clinker Granulometry

2. Clinker Distribution

3. Cooling Air Quantity

4. Cooling Air Distribution

5. Clinker Inlet Temperature

6. Bed Height / Compartment Pressure

CLINKER GRANULOMETRY

 Depending on the size of the clinker,

resistance to fan flow varies
 Coarse clinker (bigger size) has low
resistance & more air flow to pass
through
 Finer clinker has packed bed, more
resistance & thereby decreases air flow
through them
 It is always difficult to make the clinker
bed with uniform clinker granulometry
CLINKER DISTRIBUTION
 Fine & coarse clinker fall at different
position on projectile principle
 More the Kiln rpm, more is the separation
of fall position of fines & coarse
 More wider space at cooler fall point, more
difficult to clinker distribution
 Cooler width should not be more than
60% of Kiln dia.
 Horse shoe arrangement to be provided at
the cooler inlet part for better distribution
TYPICAL HOT SHOE AND DEAD
GRATE PLATE ARRANGEMENT
COOLING AIR QUANTITY
 For cooling clinker 65°C above ambient,
cooling air quantity is required 2.3
Nm3/kg clinker or 3 kg/kg clinker.
 Lowering down the cooling air quantity
leads to higher clinker outgoing
temperature & cooler vent temperature.
 Cooler with static grate of cooling air
quantity 1.6 – 1.8 Nm3/kg clinker have
higher vent air temperature & generally
clinker outgoing temperature 105 – 110°C
above ambient.
COOLING AIR DISTRIBUTION

 Recuperation efficiency of the cooler

depends on how cooling air distribution is
made.
 Total hot air for combustion (SA + TA) i.e.
0.80 – 0.85 Nm3/kg clinker has to be
distributed before “NULL” point of cooler.
 Generally for good designed cooler, the
null point is at the end of the 3rd
compartment.
DESIGN CRITERIA OF COOLER
COOLING AIR LOADING IN
DIFFERENT COMPARTMENT

Compartment Cooling Air Loading

Nos. (Nm3/min/m2)
1st Fan 115
2nd Fan 105
3rd Fan 95 0.8 – 0.85
4th Fan 80 Nm3/kg cl
5th Fan 70
6th Fan 55 Balance =
7th Fan 45 1.0 – 1.5
8th Fan 30/35 Nm3/kg cl
COOLING AIR DISTRIBUTION

Fluidization
Velocity

Velocity

115 Air density

Nm3/Min/m2
CLINKER INLET TEMPERATURE
 Higher the clinker temperature, higher is
the recuperation efficiency.
 Faster is the cooling, initial strength of
cement will improve because of C3S
crystal growth.
 Slow cooling has advantage of 28 days
strength because of C2S crystal growth.
 Hence it is a preferable to have a cooling
zone inside the Kiln so that fall of clinker
temperature on cooler is approx. 1300 –
1350°C & not 1450°C.
BED HEIGHT / COMPARTMENT
PRESSURE

 Higher the bed height, better is the

recuperation efficiency.
 Bed height = (Compartment fan pressure
– 100) mm
 Fan has to be selected for a particular
compartment with reference to 10%
higher in volume and 25% higher in
pressure.
 Fan has to be selected for a „Stiff‟ curve &
not a „Flat‟ curve nature.
PREVENTION OF SNOWMAN
FORMATION
 Cooling air loading in the compartment
as per designed norm.
 Cooler back wall preferably 70° inclined
with reference to cooler grate towards
kiln side or 110° with respect to cooler
grate towards grate movement.
 As working point of Kiln on hot condition
300 mm with reference to cooler back
wall, clinker will fall 300 mm away from
from back wall when back wall is vertical
and clinker can not be spread uniformly
over the width of the grate.
PREVENTION OF SNOWMAN
FORMATION

 If the back wall is constructed at 70°

starting from 600 mm away of vertical
wall, the clinker can be spread uniformly.
 Without inclined wall & using air blasters
is a prevention to snow man formation
but not a cure.
PREVENTION OF SIDE WALL
DAMAGE
 At least upto 4th compartment grate plate,
dead grate plates to be installed on both
sides of the cooler to protect the side wall
& cooler side frame.
 Compartment hopper bottom should have
motorised double flap dampers with level
sensors to prevent air leakages.
 Partition plates between compartments
should be perfectly maintained to prevent
air leakage.