Cement Cooler Process PDF

CLINKER COOLER
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
CONTENT
• Principle of cooler
• Types / Generation of cooler
• Working principle
• Optimizing the cooler operation
• Instrumentation and Control
11 April 2014 2
PRINCIPLE OF COOLER
11 April 2014 3
WHY DO WE NEED A CLINKER COOLER..??
1. To recuperate heat from clinker.
2. Hot clinker - difficult to convey
3. Hot clinker shows negative effect on grinding process
4. Proper Cooling improves the quality of Cement
WHY DO WE NEED A CLINKER BREAKER AT THE

COOLER DISCHARGE..??
To crush the clinker to the acceptable feed size for cement mill (Ball Mill / VRM).
11 April 2014 4
MODES OF HEAT TRANSFER INVOLVED
IN CLINKER COOLING
Heat transfer
by radiation
Heat moves
to clinker edge and convection
 Conduction by conduction
 Convection
 Radiation
Air flows over

clinker cooling
surface
11 April 2014 5
TYPES OF FLOW
Air Air Air
Material
Material Material
Parallel flow Counterflow Cross-flow
material
material material
air
T
T
air
11 April 2014 6
TYPES OF COOLER
11 April 2014 7
COOLER TYPES
 Planetary cooler
 Rotary cooler
 Grate cooler
 1st Generation Grate Coolers – conventional grate
 2nd Generation Grate Coolers – air-beam grate
 3rd Generation Grate Coolers – stationary grate
11 April 2014 8
PLANETARY COOLER
ADVANTAGES DISADVANTAGES
Operates without Excess Air High Clinker Temperature > 150 °C
Simplicity – Low Investment No TAD Capability
Common Drive (Only

Limited Capacity – No Calciner
1.5kwh/MT)
11 April 2014 9
ROTARY COOLER
ADVANTAGES DISADVANTAGES
Operates without Excess Air High Clinker Temperature > 225 ° C
Permits TAD Take-off Separate Drive ~ 3.5 kWh/MT

Higher Investment and maintenance
Low Radiation Losses
Cost
11 April 2014 10
1ST GENERATION CONVENTIONAL
GRATE COOLERS
Advantages of Conventional Grate Cooler
Ability to handle large capacities
Capable of achieving low clinker temperature
Favourable heat recuperation
Permits take out of hot tertiary air
11 April 2014 11
2nd GENERATION AIR BEAM
TECHNOLOGY COOLER
IKN – Pendulum Cooler

FLSmidth – COOLAX – CFG Cooler
Advantages of Air beam technology

Cooler
Ability to handle large capacities
Better recuperation compared to
conventional grate cooler
Improved Cooling air distribution
11 April 2014 12
3rd GENERATION – STATIONARY
GRATE COOLER
FLSmidth – CB Cooler Polysuis - POLYTRACK
KHD - Pyrofloor
Advantages of Stationary Cooler

No fall Through
Low Wear Parts
Low Cooler Loss
Low Maintenance and Power
High Efficiency
11 April 2014 13
WORKING PRINCIPLE OF COOLER
11 April 2014 14
Grate Plate
Polysuis - POLYTRACK
FLSmidth – CB Cooler
KHD Cooler - PYROFLOOR
IKN Pendulum Cooler
11 April 2014 15
FLOW REGULATOR
11 April 2014 16
FLOW REGULATOR AND CENVENTIONAL
TECHNOLOGY
11 April 2014 17
OPERATION OF FLOW REGULATOR
11 April 2014 18
VELOCITY PROFILE COMPARISION
PASSIVE ACTIVE – Flow Regulator

11 April 2014 19
Flow regulator PRESSURE DROP
11 April 2014 20
FLSMIDTH CROSS BAR COOLER
Advantages of CB Cooler
Horizontal Clinker transport
Improved Transportation efficiency
Highly flexible for new construction and upgrades
11 April 2014 21
MEASUREMENTS
&
OPTIMISING THE COOLER OPERATION
11 April 2014 22
OPTIMISING THE COOLER
TO ensure the cooler is operated efficiently, the following needs to be monitored
 Cooler Heat Balance.
 Cooler Efficiency.
 Cooler Losses.
11 April 2014 23
COOLER MASS AND HEAT BALANCE
Cooler Inputs
Clinker Input
Cooling Air Input
Fan Energy Input
Water Injection
Cooler Outputs
Secondary and Tertiary Air Calculation
Excess Air
Clinker Temperature
Cooler Radiation
11 April 2014 24
Measurements taken in cooler for
cooler heat balance
1. Cooler air fan flow
2. Cooler excess air fan flow – temperature
3. Tertiary air flow – temperature
4. Clinker temperature.
TAD - 3
Cooler excess air - 2
Kiln 4
Cooler
Cooler fans - 1
11 April 2014 25
Cooler air fan flow measurement
V – Velocity – From Anemometer readings (m/s)

A – Cross Section area of fan inlet area (m2)
ρ - Density of air (kg/m3)
ρN –Density of air at Normal Conditions – 1.293 kg/m3
t – Temperature of ambient air
Ps – Static Pressure at fan inlet
11 April 2014 26
COOLER INPUT
Clinker Input
The amount of clinker is found by physical measurement of clinker coming out of the cooler including all dust.
Clinker Input is considered as 1 kg which is taken as the basis for the Mass & Heat balance.
Total Clinker from Drop Test = 200 TPH
Clinker Input = 200/200 = 1 kg/kg Clinker
Cooling Air Input
Velocities of each fan to be measured at fan inlet using the anemometer. The flow can be found from the
formula,
Volumetric Flow Rate, Q [m3/Sec] = Velocity [m/Sec] x Fan Inlet Area [m2]
Mass Flow Rate [kg/hr] = Q [m3/Sec] x Density x [kg/m3] x3600
Specific Mass Flow = Q [kg/hr] / Total Clinker [kg/hr]

= 4,20,000/(200*1000)
= 2.1 kg/kg Clinker
Fan Energy Input
Power Consumed by all Cooler Fans = 1198 kw ** The value is at meter , 1 % Line Loss and 5 %
Fan Energy = 1198/200 Motor Loss is to be subtracted and convert it to heat
= 5.99** kwh/t (kCal/kg Clinker) by using with 0.86

Water Injection
Specific Water Flow [kg/kg Clinker] = Net Water Flow [kg/hr] / Total Clinker [kg/hr]
11 April 2014 27
COOLER OUTPUT
SECONDARY AND TERTIARY AIR CALCULATION
Typical stoichiometric combustion air amount:
LMIN = ~1.42kg air/1000kcal (low heat value)
Actual combustion air amount:
LCOMBUSTION = LMIN * λ
Where:
1
Lambda: λ 
79.1 O2
1 x
20.9 100  CO2  O2
LCOOLER = LCOMBUSTION - LP+T - ΣLFALSE

11 April 2014 28
Cooler Excess Air Fan – Flow measurement
 f – Pitot Tube Constant (0.8-0.85)

 Pd – Dynamic Pressure (Pa) – from Pitot Tube Measurement
 g – Acceleration of gravity (m/s2)
 A – Cross Section of duct (m2)
11 April 2014 29
COOLER OUTPUT
EXCESS AIR
The cooler Excess air can be found by measuring the temperature and static pressure at
cooler ESP inlet or ESP fan inlet or at Cooler ESP Stack.
From Stack Cooler Excess air will be found by back calculation as follows.
1. Gas inlet condition

2. Leak air inlet condition
3. Gas outlet condition
11 April 2014 30
COOLER OUTPUT
Clinker Temperature
Clinker temperature is to be measured by taking clinker samples in an insulated closed container.
Clinker considered for measurement must be sieved in – 12 mm and + 6 mm sieves.
Coating pieces and red hot pieces must be removed.
It is recommended to take the samples before Clinker crusher.
This is mainly because coating pieces will be crushed in clinker crusher zone and this must be
avoided.
Cooler Radiation
Cooler radiation is calculated from the surface temperature and surface area.
In general cooler radiation for modern cooler will be around 6 kcal/kg Clinker.
11 April 2014 31
Specific heat calculation (Cp)
11 April 2014 32
Summary of measurements
 Cooler input air – Mass – Temperature

 Cooler excess air – Mass – Temperature
 Tertiary Air – Temperature
 Clinker temperature at cooler outlet
 Fan Energy
Summary of calculation
 Secondary and tertiary air – Mass / Flow

 Radiation loss
 Specific heat of all parameter with reference to the measured
temperature
11 April 2014 33
Typical Cooler Mass and Heat Balance
Cp
Input Flow kg/kg Temp °C Ref = 0 Ref amb.
Kcal/kg/°C
Clinker 1.000 1450 0.264 383.0 381.3
Dust 0.050 1450 0.264 19.2 19.1
Cooling Air 1.928 10 0.237 4.6 0.0
Fan Energy in kWh/t 5.99 5.2 5.2
Water Injection 0.000 15 1 0.0 0.0
Total Heat, In 411.9 405.4
Cp
Output Flow kg/kg Temp °C Ref = 0 Ref amb.
Kcal/kg/°C
Secondary Air 0.312 1119 0.262 91.5 90.7
Secondary Air Dust 0.020 1119 0.245 5.5 5.4
Tertiary Air 0.703 1020 0.262 187.9 186.2
Tertiary Air Dust 0.030 1020 0.244 7.5 7.4
Excess Air 0.914 375 0.238 81.6 79.4
Excess Air Dust 0.000 375 0.195 0.0 0.0
Clinker 1.000 165 0.194 32.1 30.3
Radiation 6.0 6.0
Heating + Evaporation of Water 0.00 579 0.0 0.0
Total Heat, Out 411.9 405.4
11 April 2014 34
AIR LOAD CALCULATIONS
Cooler Air Load is the ratio of the amount of air supplied to the cooler
loading area.
COOLER SPECIFIC AIR

Cooler Specific Air is the ratio of the amount of air supplied to the clinker
production.
11 April 2014 35
EXAMPLE FOR AIR LOAD AND SPECIFIC AIR
Air flow Specific Air Area Air Load

Fans
m3/min Kg/min Kg/Kg Clk m2 kg/min/m2
FN01-K11 1332.24 1555.74 0.28 13.65 113.97

Here is an example of air
FN02-K21 923.04 1077.89 0.19 10.92 98.71 load calculation for a
FN03-K22 1374.77 1605.40 0.29 16.38 98.01 complete cooler.
FN04-K31 860.55 1004.91 0.18 10.92 92.02
Kiln Feed = 550 TPH
FN05-K32 1282.78 1497.98 0.27 16.38 91.45
Kiln Production=8049 TPD
FN06-K41 1457.404 1700.79 0.304 27.30 62.30
Density= 1.167 kg/m3
FN07-K51 1393.08 1626.78 0.29 27.30 59.59
FN08-K61 1305.31 1524.29 0.273 27.30 55.83
Total 9929.174 11594 2.077 150.15
11 April 2014 36
COOLER LOADING
The cooler loading is defined as the amount of clinker over the grate area.
Cooler Loading for the above example is calculated as
Cooling Air (kg/kg

Cooler Type Maximum Loading (TPD/m2)
Clk)
Rotary Cooler 38 3.3
Grate Cooler 50 2.55
Cross Bar
46 2.3
Cooler
11 April 2014 37
COOLER EFFICIENCY
 Better Clinker quality
 Higher cooler efficiency - Lower specific fuel consumption
 Lower clinker temperature - Handling clinker shall be much

more easier
 Other Indirect benefits …
 Reduction in PH fan power consumption
11 April 2014 38
COOLER EFFICIENCY
The efficiency of a cooler is defined as the relationship between the recuperated
heat to the kiln and the total heat transferred to the cooler.
Where,
Cooler Loss = (TKO x SKTKO) + (MEX x TEX x SATEX) + RA
TKO = Temperature of clinker leaving the cooler
SKTKO = Specific Heat of Clinker leaving the cooler
MEX = kg of excess air per kg of clinker
TEX = Temperature of excess air
SATEX = Specific heat of excess air
MCA = kg of cooling air per kg of clinker
TCA = Temperature of cooling air
SATCA = Specific heat of cooling air
RA = Cooler housing radiation in kcal/kg of clinker
11 April 2014 39
What is Cooler efficiency???
Cooler efficiency =
11 April 2014 40
Heat Available / Heat Input
• Heat content of clinker from kiln (Clinker–1450°C)
• Heat content of cooler air (ambient air)
Cooler
11 April 2014 41
Heat loss
 Heat content of cooler vent gas
 Radiation
 Heat content of clinker at exit
Radiation
Cooler
11 April 2014 42
Tertiary Air
Heat Recuperated Cooler / Heat loss

Radiation
Secondary Air
Cooler
Heat Input
11 April 2014 43
Basis of Cooler loss
 Actual Cooler loss
 VDZ Cooler loss
 Standard Cooler loss
11 April 2014 44
Actual Cooler loss (ref 0°C)
Actual Cooler loss = Heat Content of clinker at 0°C

+
Heat Content of excess air at 0°C
+
Radiation loss
11 April 2014 45
VDZ Cooler loss (ref ambient air °C)
Verein Deutscher Zementwerke – German Cement Works Association
VDZ Cooler loss = Heat Content of clinker w.r.t amb°C

+
Heat Content of excess air w.r.t amb°C
+
Radiation loss
11 April 2014 46
Standard Cooler loss (ref ambient air °C)
Standard Cooler loss basis
•Combustion air – 1.15 kg/kg clk
Standard Cooler loss (kcal/kg clinker)

= Heat Content of clinker w.r.t amb°C +
Heat Content of excess air w.r.t amb°C +
Radiation loss
11 April 2014 47
OVERALL COMPARISON
Total Cooler Loss
VDZ Cooler Loss (Net Cooler Loss Ref Cooling Air Temperature)
Standard Cooler loss (Normalize)

Standard Cooler loss (kcal/kg clinker)
= Heat Content of clinker w.r.t amb°C +

Heat Content of excess air w.r.t amb°C +
Radiation loss
11 April 2014 48
ACTUAL LOSS Vs STANDARD LOSS
11 April 2014 49
Summary of cooler performance
 Cooler loss – From heat balance

 Cooler efficiency – From formula
 Clinker temperature – From measurement
Cooler parameters Bench Mark Your cooler

Values
Standard Cooler loss ≤ 95
(kcal/kg clinker)
Cooler efficiency (%) ≥ 75%
Clinker temperature (°C) ≤ 65+ambient
11 April 2014 50
Possible reasons for cooler inefficiency
 Grate plates worn out (Applicable for 2nd generation cooler)

 Insufficient cooler air
 Clinker bed – not optimum
 Too high cooler width / grate load
 Clinker PSD – Too fine clinker – This shall lead to red river, if not
cooled initially.
 Clinker chemistry
11 April 2014 51
Typical Comparison Table of all Cooler Loss
Planetary Cooler Conventional Grate Cooler
Radiation 97 Radiation 6
Excess Air 0 Excess Air (1.85 kg/kg @ 240 deg C) 108
Clinker (150 deg C) 25 Clinker (90 deg C) 17
Total Loss 122 kcal/kg Total Loss 131 kcal/kg
Rotary Cooler Air Beam Grate Cooler
Radiation 75 Radiation 6
Excess Air 0 Excess Air (1.2 kg/kg @ 240 deg C) 70
Clinker (225 deg C) 45 Clinker (90 deg C) 17
Total Loss 120 kcal/kg Total Loss 93 kcal/kg
Cross Bar Cooler
Radiation 6
Excess Air (1.0 kg/kg @ 240 deg C) 58
Clinker (90 deg C) 17
Total Loss 81 kcal/kg

11 April 2014 52
COOLER LOSS – A TYPICAL COMPARISION STUDY
Conventional Cooler Air Beam Cooler Cross Bar Cooler

Parameters
Mass Temp Heat Mass Temp Heat Mass Temp Heat
Kiln Exit 1 1450 383 1 1450 383 1 1450 383
Cooling Air 3.10 35 26 2.55 35 21 2.15 35 18
Sec Air 0.45 1070 126 0.45 1220 145 0.45 1260 150
Tertiary Air 0.65 750 124 0.65 815 135 0.65 870 145
Excess Air 2.0 265 130 1.45 270 95 1.05 295 75
Clinker 1 100 19 1 100 19 1 100 19
Radiation - - 11 - - 11 - - 11
Total Loss - - 160 - - 125 - - 105
STD Loss - - 130 - - 100 - - 85
Note : Mass in kg/kg Clinker , Temp in deg C & Heat in kcal/kg

All the three coolers has the same combustion air but the cooler loss reduced by 55 kcal/kg in
Cross Bar cooler when compared to conventional cooler.
The excess air which is the major loss in cooler is reduced to 1 kg/kg Clinker and where as heat
reduced to heat 75 kcal/kg.
The Cooling air input is reduced from 3.10 to 2.15 kg/kg Clinker.
11 April 2014 53
EXAMPLE
For clear understanding this can be discussed with an example.
Note:-
Let's consider, P = 200 TPH, NCV = 5500 kcal/kg, then saving in
It must be noted we have
fuel is,
projected only the heat savings.
Specific Heat Saving = Conventional Cooler Loss – SF Cooler Loss We will have additional savings in
= 160 – 105 electrical consumption because of

following reasons.
= 55 kcal/kg
Heat Saving = 55 x 200 x 1000 Reduction in input cooling air
= 11 x 106 kcal/hr reduces the number of fans

required for fans required for
Fuel Saved = 11 x 106/5500
system.
= 2000 kg/hr
= 2 tons/hr i.e., 48 tons/day Subsequent reduction in excess air
quantity will gave some benefits in
Assume Cost of 1 ton coal = 53 €
terms of power savings in cooler
Amount Saved per day = 53 € x 48 vent fan.
= 2,533 € /day
Amount Saved per annum (330 Days) = 76320 € /annum
11 April 2014 54
1st Generation Cooler
11 April 2014 55
2nd Generation Cooler
11 April 2014 56
3rd Generation Cooler
11 April 2014 57

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CLINKER COOLER

2. Hot clinker - difficult to convey

3. Hot clinker shows negative effect on grinding process

4. Proper Cooling improves the quality of Cement

WHY DO WE NEED A CLINKER BREAKER AT THE

Air flows over

Air Air Air

Parallel flow Counterflow Cross-flow

 1st Generation Grate Coolers – conventional grate

 2nd Generation Grate Coolers – air-beam grate

 3rd Generation Grate Coolers – stationary grate

Operates without Excess Air High Clinker Temperature > 150 °C

Simplicity – Low Investment No TAD Capability

Common Drive (Only

Operates without Excess Air High Clinker Temperature > 225 ° C

Permits TAD Take-off Separate Drive ~ 3.5 kWh/MT

IKN – Pendulum Cooler

Advantages of Air beam technology

Advantages of Stationary Cooler

KHD Cooler - PYROFLOOR

IKN Pendulum Cooler

PASSIVE ACTIVE – Flow Regulator

OPTIMISING THE COOLER OPERATION

TO ensure the cooler is operated efficiently, the following needs to be monitored

 Cooler Heat Balance.

V – Velocity – From Anemometer readings (m/s)

Specific Mass Flow = Q [kg/hr] / Total Clinker [kg/hr]

Fan Energy = 1198/200 Motor Loss is to be subtracted and convert it to heat

= 5.99** kwh/t (kCal/kg Clinker) by using with 0.86

SECONDARY AND TERTIARY AIR CALCULATION

Typical stoichiometric combustion air amount:

LMIN = ~1.42kg air/1000kcal (low heat value)

Actual combustion air amount:

LCOOLER = LCOMBUSTION - LP+T - ΣLFALSE

 f – Pitot Tube Constant (0.8-0.85)

1. Gas inlet condition

 Cooler input air – Mass – Temperature

 Secondary and tertiary air – Mass / Flow

Heating + Evaporation of Water 0.00 579 0.0 0.0

Total Heat, Out 411.9 405.4

COOLER SPECIFIC AIR

Air flow Specific Air Area Air Load

FN01-K11 1332.24 1555.74 0.28 13.65 113.97

Total 9929.174 11594 2.077 150.15

Cooler Loading for the above example is calculated as

Cooling Air (kg/kg

 Better Clinker quality

 Higher cooler efficiency - Lower specific fuel consumption

 Lower clinker temperature - Handling clinker shall be much

 Other Indirect benefits …

 Reduction in PH fan power consumption

• Heat content of clinker from kiln (Clinker–1450°C)

• Heat content of cooler air (ambient air)

Heat Recuperated Cooler / Heat loss

 Actual Cooler loss

 VDZ Cooler loss

 Standard Cooler loss

Actual Cooler loss = Heat Content of clinker at 0°C

Verein Deutscher Zementwerke – German Cement Works Association

VDZ Cooler loss = Heat Content of clinker w.r.t amb°C

Standard Cooler loss basis

•Combustion air – 1.15 kg/kg clk

Standard Cooler loss (kcal/kg clinker)