ENGINEERING FOR MODERNIZATION OF A CLINKER COOLER

Authors: Willian Carabali & Carlos Fernández, SATAREM

February 2019

1. Summary

SATAREM completed the engineering to modernize a 2,100 TPD Folax cooler for a cement plant in
Latin America. The use of software tools combined with a long history in modification of clinker
coolers allowed to create an innovative solution that will allow to improve kiln system
performance while considering restrictions of space, existing equipment and on-site process
conditions. Modified cooler will reduce cooler downtime by 50%, reduce heat consumption by 5%
and increase output but 7%.

2. Proposed diagnostic and modifications

Initially, SATAREM carried out an on-site diagnostic, which allowed identifying operational and
design problems. Regarding operational problems it was evidenced, for example, that system had
frequent "red river" and clinker outlet temperature around 200°C. On other hand, in relation to
mechanical design, there were frequent damages to kiln seal due to static inlet installed near kiln
nose ring, burning to cooler plates and frequent stoppages due to failures on mechanical drive. All
above elements cause loss of clinker production and increase of heat consumption.

Figure 1. Proposed arrangement on current casing

Calle 13 No. 23D – 24. Local 9

Cali, Colombia
www.satarem.co
Once operating parameters and design characteristics were analyzed, SATAREM proposed to
replace mobile grates 2 and 3 keeping existing static inlet but at a lower level than current one.
Likewise, replacement of second-generation mechanical drive by a state-of-art hydraulic drive,
new connecting shafts, new fixed and mobile beams, replacement of perforated plates by
SATAREM 201 pocket plates, SATAREM guillotine valves and a new rollers crusher.

complete modification will be implemented keeping existing casing and most of fans, which will
allow considerable savings for dismantling, assembly and civil works, as well as a reduction in
downtime due to cooler project implementation.

3. Improvement of Gas Flow

On "bull nose" area problems of excessive wear due to secondary air high speed are common,
leading to deterioration and premature falling of refractory. To decrease speed of secondary air
towards kiln, first section (static inlet and first mobile grate) was moved downwards, leveling it
with second section (second mobile grate).

When lowering fixed grate and first mobile grate this modification solves two problems: 1.
Increasing hot gases passage area at "bull nose" therefore reducing gases speed by 21.2% and 2.
Eliminating premature damage of kiln seal by increasing distance between kiln nose and clinker
bed.

Illustration 1. Current Flow ratel (14.05 m/s) Illustration 2. Flow rate when lowering grate (11.07
m/s)

Figure 2. Current and modified velocity analysis

4. Main elements of SATAREM technology

The improved design of SATAREM cooler includes some key elements that allow to increase both
efficiency of heat recovery and clinker transport, these elements are:

Calle 13 No. 23D – 24. Local 9

Cali, Colombia
www.satarem.co
Mobile grate SATAREM:
 SATAREM grate has a partition in its chassis
to counteract deformations due to thermal
expansion.
 design of fixed and mobile beams allows a
better air flow towards cooler plates and
their design is more robust and resistant.
 bolt system between beam and plates
allows application of load in direction of
movement, eliminating damages due to
shear stress.
 mobile chassis is modular, allowing easy
assembly on site.

SATAREM 201 plates:

These plates have three characteristics to
highlight in relation to traditional design:
 They are "pocket" type plates which
ensures a cold clinker bed, protecting
plates.
 Aeration slots improve ventilation while
reducing clinker drop to cameras
 They are manufactured with special alloy to
withstand high temperature and high
abrasion condition, allowing high service
life.

Hydraulic drive:
For this cooler it is proposed to install a
hydraulic unit to replace the old-design
mechanical units. Hydraulic drives are more
reliable and requires almost no maintenance,
thus improving cooler running factor.

Some of its characteristics are:

 stroke can be adjusted to as well as pace
for forward and backward movement.
 It reduces electricity consumption.
 It allows maintenance in operation because
it has a backup system.

Calle 13 No. 23D – 24. Local 9

Cali, Colombia
www.satarem.co
 Flow control valves:

SATAREM guillotine valves have a key feature,

which is that they allow a good sealing between
fine recovery hopper and drag chain. This will
increase cooler efficiency.

Compared to double flap type valves, SATAREM

guillotine valve is guide by side lips that prevent
deformation, ensuring a perfect airtightness
with controlled position detectors.

This valve is activated by means of a pneumatic

cylinder that can be connected to circuit of
existing air of plant.

5. Cooler New Specifications

TECHNICAL PARAMETERS COOLER UPGRADE

Capacity 2,300 TPD
Clinker outlet temperature 80 + T amb °C
Static inlet Yes -
Mobile grates 2 - 
Grate width II y III (net) 2,4 m
Static grate length 2.8 m
Grate length II 10.4 m
Grate length III 9.0 m
Total cooling area 51.5 m2

6. Results

Based on simulation carried out and based on other modifications made by SATAREM Group, the
new system:

 Improves heat recovery efficiency by increasing secondary air temperature from 810 to 900°C.
 Guarantees clinker outlet temperature at 80 ° C + T ambient.
 Improves running factor by reducing cooler stops by 50% at least.
 Allows increasing, in a sustained way, kiln output to 2,300 TPD.

Calle 13 No. 23D – 24. Local 9

Cali, Colombia
www.satarem.co