Cooler Efficiency

Attapong Sathitmanothum
Cement (Thung Song)
30 June 2005

Siam Cement Industry Co.,Ltd.

Clinker Cooler : Grate System

Tertiary Air Excess Air

Secondary Air

Hot clinker

Cooled clinker

Cooling Air

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Grate Cooler Heat Losses

1. Excess air 88%

2. Clinker leaving the cooler 9%
3. Radiation loss 3%

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Major Types of Cooler Loss

• Total Cooler Loss
– Reference temperature = 0 deg.C
• VDZ Cooler Loss
– Cooling air temperature as reference point
• Standard Cooler Loss
– Normalized combustion air 1.155 kg/kg clinker
– Cooling air temperature as reference point

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Cooler Efficiency
Eff. = 100 – 100 x Cooler Loss
Hot clinker + Cooling air

Cooler loss = TKO x CPTKO + MEX x TEX x CPTEX + RA

TKO : temperature of clinker leaving cooler 1450 oC

TEX : temperature of excess air
CPTKO : specific heat of clinker at temp. TKO (oC)
CPTEX : specific heat of air at temp. TEX (oC)
RA : radiation loss

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VDZ Cooler Efficiency

Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power)

Max. heat release clinker

Max. heat release clinker is Heat content of clinker

at the kiln discharge temperature 1450 deg.C

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Example of Cooler Efficiency
Tertiary Air Excess Air
0.79 kg/kg, 770 oC 1.6 kg/kg, 251 oC

Secondary Air
0.41 kg/kg, 1062 oC

Hot clinker
1 kg, 1400 oC

Cooled clinker
1 kg, 122 oC
Secondary Air
0.41 kg/kg, 20 oC Tertiary Air
0.79 kg/kg, 20 oC
Excess Air
1.6 kg/kg, 20 oC

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Cooler Heat Balance

Heat input kg/kg oC kcal/kg oC kcal/kg
Clinker 1.000 1400 0.262 367
Dust 8% 0.080 1400 0.262 29
Secondary air 0.410 20 0.237 1.9
Tertiary air 0.790 20 0.237 3.8
Excess air 1.600 20 0.237 7.6
Power cons. 6kWh/t x 0.86 x 0.85 4.4
Sum 414
Heat output kg/kg oC kcal/kg oC kcal/kg
Clinker 1.000 122 0.193 24
Dust 0.080 1062/770 0.234/0.229 16
Secondary air 0.410 1062 0.261 114
Tertiary air 0.790 770 0.225 155
Excess air 1.600 251 0.243 98
Radiation 7
Sum 414

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Total Cooler Loss
Reference Temperature = 0 deg.C

• Excess air 98 kcal/kg.cli

• Clinker leaving cooler 24 kcal/kg.cli
• Radiation 7 kcal/kg.cli
• Total cooler loss 129 kcal/kg.cli

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VDZ Cooler Loss

Reference temp. = cooling air temp (20 deg.C)
• Excess air 90.4 kcal/kg.cli
– Excess air at 251 oC +98 kcal/kg.cli
– Excess air at 20 oC -7.6 kcal/kg.cli
• Clinker leaving cooler 20 kcal/kg.cli
– Clinker at 122 oC 24 kcal/kg.cli
– Clinker at 20 oC (0.189 x 20) -4 kcal/kg.cli
• Radiation 7 kcal/kg.cli
• Total cooler loss 117 kcal/kg.cli

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Heat absorption of combustion air
Hot clinker from kiln 363 kcal/kg.cli
- Hot clinker at 1400 oC 367 kcal/kg.cli
- Hot clinker at 20 oC (0.189x20) -4 kcal/kg.cli
Power of Fan +4.4 kcal/kg.cli
Clinker leaving cooler -20 kcal/kg.cli
- Clinker at 122 oC 24 kcal/kg.cli
- Clinker at 20 oC (0.189 x 20) -4 kcal/kg.cli
Excess air -90.4 kcal/kg.cli
- Excess air at 251 oC +98 kcal/kg.cli
- Excess air at 20 oC -7.6 kcal/kg.cli
Radiation -7 kcal/kg.cli
Heat absorption 250 kcal/kg.cli
or : Hot clinker at 1400 oC +Fan power– VDZ cooler loss

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Maximum heat released

Maximum heat released 363 kcal/kg.cli

- Hot clinker at 1400 oC 367 kcal/kg.cli
- Clinker at 20 oC -4 kcal/kg.cli

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Cooler efficiency
Reference at 0 deg.C

Eff. = 100 – 100 x Cooler Loss

Hot clinker + Cooling air

= 100 - 100 x 129

367 + 13.3

= 66.1 %

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VDZ Cooler Efficiency

Reference at cooling air temperature
Heat absorption of combustion air

Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power)

Max. heat release clinker

= 100 – 100 x (117 – 4.4)

363
= 68.9%

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VDZ cooler loss vs. Combustion Air

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Example

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Cooler Loss vs. Combustion Air

Combustion air (kg/kg cli)

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Cooler eff. vs. Combustion Air

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 End

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