Clinker Cooling

Cooler Modification- New solution for

todays market demands

Alexis Lua - Claudius Peters

The Golden Days
• Do you remember • Claudius Peters
when: remembers
• Cement demand was
high
• Competition was low
• Energy prices where
stable
• Environmental
regulations where
minimal
• Investment money was
ready available $$$
Today
• Cement price is low
• Competition is high
• Energy price is high
• Environmental regulations
are though
• Investment cuts eminent $
Claudius Peters solution:
• New cooler technology
• Efficient = decrease energy
and fuel cost
• Closed system =
environment friendly
• Short Return of Investment
My cooler comes from the Golden Days
COOLER MODIFICATION

Increase efficiency

Reduce Maintenance Costs

Always available

SAVE $$$
EFFICIENCY

Modern Traditional
ETA Cooler Grate Cooler

Bed height 950 mm 600 mm

Clinker retention Time @ 45 t/d/m² 42,6 min 26,9 min

Power consumption 4,89 kWh/t clinker 4 kWh/t clinker

Cooler Efficiency 77,8 % 73,9 %

 MAINTENANCE
ETA Cooler Grate Cooler

Self-protected design Burnt and broken grate plates,

with pebbles and high due to direct hot clinker
clinker layer contact

Photo courtesy of client

Hard facing Lane filling with
pebbles
MAINTENANCE
After 4 years

After 9 years

Only paint is off

the cooler is ready
for production

Photo courtesy of client

MAINTENANCE
• Heavy duty rollers

Siggenthal / Switzerland 02/2015

Siggenthal / Switzerland
Rollers after 6 years after 10½ years of operation
• Designed for fatigue strength and continuous operation
• Slow movement and hard faced surfaced
• Greasing once a year only
• Never replaced a roller since 2004
AVAILABILITY
Modern Traditional
Failure mode:
ETA Cooler Grate cooler
By-pass is opened, clinker Stand-by pump must be
Failure of one pump
production continues activated

Failure of one lane drive Production continues Production stop

Failure of 2 lane drives Reduced production continues Production stop

DESIGN BONUS
ETA Cooler-Walking floor tech

No red river Thermal homogenization

No snow man Controlled Side Aeration (CSA)

Longer drag conveyor and filter life

Cool clinker
time
2-4 strokes /min = fast cooling ,
Stroke Length
high quality clinker
HE Module flex
Accurate aeration control
air

HE Module Cross sealing for max plate lifetime

Experience More than 800 coolers sold

Pioneers More than 100 years of innovation

Smaller HD fan Lower combustion gas vol.

OLD out NEW in

COOLER MODIFICATION

NEW SOLUTION FOR TODAYS

MARKET DEMANDS
MODIFICATION
Capacity: 3700 t/d
Aerated Area: 71,1 m²
Grate Load: 52,1 (t/d)/m²

Separate Bypass ??
11 m/s !!
6,3 m/s

1 3
13,9 m/s !!!
2

New parts: pre-asambled ETA Existing upper steel &

lane units refractory

New roller crusher Extension cooler upper

part
MODIFICATION

New parts: pre-erected ETA lane

units
Existing upper steel &
refractory
Modified side walls
MODIFICATION

2 Lane Unit 3 Lane Unit

Essential design features:

 fully modular construction

 local fabrication maximized
 flexible module arrangement for existing
plants
 pre-assembled modules to site

Fast installation – minimized kiln shut down time

MODIFICATION

Stage Cooler Modification- Quantou Group, China

MODIFICATION
Existing small exhaust Exist. Exhaust Main Exist. WHR
 New exhaust  New WHR  New Mill Air

Heat Content
16,5 MW

Stage Cooler Modification- Quantou Group, China

 MODIFICATION

Stage Cooler Modification- Quantou Group, China

IS MY COOLER SUITABLE FOR MODIFICATION?
 CASE STUDY
Operation Cost comparison ETA Cooler Existing Polysius SR4840
[Euro/a] [Euro/a]
Capacity 7800 t/d 7800 t/d
Increased capacity @ constant ph fan speed 471 t/d
1: Cooler availability 99,9% 96,3%
Cement production [t/a] 2.571.426 2.478.762
Clinker profit [€/a] 33.801.300 €/a 3.974.700 €/a 29.826.600 €/a 0 €/a
Operation Cost comparison ETA Cooler [Euro/tclinker ] Grate Cooler [Euro/tclinker ]
2: Cooler efficiency 78,3% 67,0%
Specific Fuel cost [Eur/tclinker] 10,63 11,49
3: Power con. Cooler[kwh/tclinker] [Fans only] 4,34 4,0
Specific power cost [Eur/tclinker] 0,43 0,40
4: Maintenance Cost [Eur/tclinker]* 0,012 0,039
5: Exhaust air Volume [Nm³/kg] 0,788 1,24
Specific power cost [Eur/tclinker] 0,084 0,20
6: Preheater Exit Gas Volume [Nm³/kg] 1,45 1,53
Power consumption [Eur/tclinker] 0,697 0,837
Flexible operation cost [Eur/tclinker ] 11,86 €/t 12,97 €/t
Fixed operation cost [Eur/tclinker ] 15 €/t 15 €/t
Sales price clinker [Eur/tclinker ] 40 €/t 40 €/t
Profit clinker [Eur/tclinker ] 13,14 €/t 12,03 €/t
CASE STUDY Return on Investment
Preliminary Non Committal
CAPITAL COST 4.588 TEUR
BENEFIT PER MONTH 331 TEUR 48 months calculation
BENEFIT EFFECTIVE IN 9 Month

INTEREST 2% IRR yearly 65,0%

MONTH EXPENSE EXPENSE INCOME NET FLOW DISCO DISCO CUM
% TEUR TEUR TEUR FACTOR FLOW FLOW
1 30% 1.376 - (1.376,3) 1,00 (1.376,3) (1.376,3)
2 0% - - - 0,9983 - (1.376,3)
3 0% - - - 0,9967 - (1.376,3)
4 0% - - - 0,9950 - (1.376,3)
5 0% - - - 0,9934 - (1.376,3)
6 0% - - - 0,9917 - (1.376,3)
7 70% 3.211 - (3.211,3) 0,9901 (3.179,3) (4.555,6)
8 - - - 0,9884 - (4.555,6)
9 - 331,3 331,3 0,9868 326,9 (4.228,7)
10 - 331,3 331,3 0,9851 326,4 (3.902,3)
11 - 331,3 331,3 0,9835 325,8 (3.576,5)
12 - 331,3 331,3 0,9818 325,3 (3.251,2)
13 - 331,3 331,3 0,9802 324,7 (2.926,4)
14 - 331,3 331,3 0,9786 324,2 (2.602,2)
15 - 331,3 331,3 0,9770 323,7 (2.278,6)
16 - 331,3 331,3 0,9753 323,1 (1.955,4)
17 - 331,3 331,3 0,9737 322,6 (1.632,8)
18 - 331,3 331,3 0,9721 322,1 (1.310,8)
19 - 331,3 331,3 0,9705 321,5 (989,3)
20 - 331,3 331,3 0,9689 321,0 (668,3)
21 - 331,3 331,3 0,9672 320,4 (347,8)
22 - 331,3 331,3 0,9656 319,9 (27,9)
23 - 331,3 331,3 0,9640 319,4 291,5
24 - 331,3 331,3 0,9624 318,9 610,3
25 - 331,3 331,3 0,9608 318,3 928,6
26 - 331,3 331,3 0,9592 317,8 1.246,4
27 - 331,3 331,3 0,9576 317,3 1.563,7
28 - 331,3 331,3 0,9560 316,7 1.880,4
29 - 331,3 331,3 0,9544 316,2 2.196,6
30 - 331,3 331,3 0,9529 315,7 2.512,3
31 - 331,3 331,3 0,9513 315,2 2.827,5
32 - 331,3 331,3 0,9497 314,6 3.142,1
33 - 331,3 331,3 0,9481 314,1 3.456,2
34 - 331,3 331,3 0,9465 313,6 3.769,8
35 - 331,3 331,3 0,9450 313,1 4.082,8
36 - 331,3 331,3 0,9434 312,5 4.395,4
37 - 331,3 331,3 0,9418 312,0 4.707,4
CASE STUDY

Replace your Cooler

Save € 4.000.000/yr
SUCCESS STORIES
JOIN THE ETA EVOLUTION

23
Sources

• https://www.lottosend.com/blog/can-money-buy-happiness-this-lottery-winner-thinks-so
• http://i.dailymail.co.uk/i/pix/2015/05/03/21/2843B78000000578-0-image-m-154_1430686303059.jpg