Design Clinker Cooler

Page 1 SilzR 24 Jun 2005 S:\Team\Training\SONGIFA\021-3-Klinkerkühler\ClinkerCoolerREPOL1.
ppt
Page 2 SilzR 24 Jun 2005 S:\Team\Training\SONGIFA\021-3-Klinkerkühler\ClinkerCoolerREPOL1.ppt
REPOL
Arrangement
REPOL with end crusher
Recuperation zone
General Design of REPOL
Hydraulic drive
Aeration ducts
for static grate
Central beam
Grate driving beam

Repol
bullnose
double
pendulum hydraulic hammer crusher/
flaps drive roller crusher
grate plate
support beams
central guidance grate grate support
supporting
roller
fans
REPOL, grate
Static grate Gußkörper: 1.4825, Verschleißplatte: 1.4828
Gußkörper: 1.4825, Verschleißplatte: 1.4762 + Eurodur 2800
Grate Gußkörper: 1.4825, Verschleißplatte: 1.5415 + Eurodur 2000
Gußkörper: 1.4825, Verschleißplatte: 1.4762 + Eurodur 2800 (einsetzbar bis 900 °C)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
1
2
3
4
5
6
7
8
9
10
F F F F F F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F B F F F
REPOL
The Static Grate

The static grate

• Static aeration zone
• Suitable clinker distribution to avoid red river
• Autogenous wear protection of cooler inlet
Aeration of the static grate

Static grate with nozzles
Air cannons
The static grate - Air blast nozzles

The static grate - Plate fixation

The static grate

REPOL
The Moving Grate

Gelenk
Antriebsträger
Schwingholmträger
Gelenk
Schwingholmträger
REPOL 2000, Schwingrost
General Design of REPOL
Hydraulic drive
Aeration ducts
for static grate
Central beam
Grate driving beam

Bearing of oscillating frame
rim
supporting roller
fixed Support beam

Central guidance
Central guidance
Sealing of partition wall
Konstant
Design criterias:
• Specific area load: max. 50 tpd/m²
• Installed cooling air: up to 2.3 Nm³/kgCli

Kiln capacity related to grate width of REPOL

Clinker Coolers
12000
upper limit
Kiln capacity [tpd]
10000 number of strokes: 15 1/min

excaption: 18 1/min
8000
6000
4000
2000 lower limit
lateral distribution of clinker
0
7 8 10 12 14 16 18 20
plates in the width [-]
Cooler REPOL
theoretical dimensioning and operating results
30
number of strokes [1/min]
25
20
max. strokes
15 min. strokes
operating results
10
0
500 1000 1500 2000
width loading [t/d m]
Clinker End Temperature as Function of

Crushed Clinker
Clinker 350
End
Temp. 300
[°C] 250
200
150
100
50
0 10 20 30 40
Amount of Crushed Clinker [%]
crushed clinker at 400°C crushed clinker at 600 °C
REPOL
The Jet Stream Plate

Details of Grate
The JET STREAM Plate

The JET STREAM Plate - principle drawing
Cast Material
Wear protection
material
Demands made on plates and grate Solution for plates and grate
Jetstream plate
Areas of wear
High resistance to abrasion > 60 HRC (harder than clinker)
High heat resistance up to 700 °C
Good cooling of the plate

Dense network of aeration slots 6 rows of slots per plate
Narrow slots 2.5 mm
Sufficient air velocity 30 - 40 m/s
Grate
Gap for moving 2 mm
The JET STREAM Plate - Wear Test
Kg
Wear plate
Wear rates of the different materials
Wear [g]
17,30
6
4,97
2,40
2 1,64
1,18
0,41 0,35 0,25

0
St3
7
l atte ur -Q
u r - L tion, it i on,
80 00 e tal l
i ng P Eurod u rod deposi d
s
epo r ed a b ro D urm
der nteredowde e-sint reus
R E r e
Jet Po w si P c C
me- rna
fla fu
Jetstream plate - service life related to wear

achieved
400000
350000
service life in [tCli/plate]
300000
250000 expected
200000
150000
100000
50000
0
0,5 1 1,5 2 2,5 3 3,5 4
Wear of the plate in [mm]
Jetstream plate - service life related to wear

1000000
900000
service life in [tCli/plate]
800000
700000
600000
500000
400000
300000
200000
100000
0
0,5 1 1,5 2 2,5 3 3,5 4
Wear of the plate in [mm]
service life dep. on wear cumulated service life

Operational results of the Jetstream plates
Codeword Year of Clinker Cooler Service Expected

commis- production width* life of service life
sioning of to this day plates** of plates
Jetstream
plates
Quantity
Mio. t of plates t / plate t / plate
Schwenk KG, 1996 5.25 12 440.000 > 600.000

Bernburg
Gap: Gap: 1370
First grate 2 mm < 3 mm tons-day
/m
Jetring plates: 150,000 to 250.000 t / plate
* Parameter for numbers of strokes / time.

**No competitor reached this service lifetime
for the plates.
Grate riddlings in the case of Jetstream plates

(data recorded of 2 chambers)
Customer / Codeword Grate riddlings
Measuring results referred to

100 m² of grate surface and 24 h of
operation
Schwenk KG, Bernburg 1200 kg of clinker dust / 100 m²

(direct aeration) 24 h
Milke Zement, Geseke 900 kg of clinker dust / 100 m² 24 h

(direct aeration) 900 kg of clinker dust / 100 m² 24 h
(chamber-type aeration)
Fastening of the grate plate

Optimized lateral guidance of the plate

REPOL, Details of grate

Seal between the grate plates

Lateral seal
Seitliche Abdichtung
Lateral Seal





Cover bar
REPOL
The Aeration
Aeration system for a REPOL Cooler
Grate 1 STATIC GRATE
Chamber-aeration
Cooling air fan number : 9
Specific load : 45 - 50 t/d.m²
Specific volume : 2.1 Nm3/kg-ck
Grate 2
Chamber-aeration
Optimized aeration and sealing air ratio 7:1
FIXED ROW MOVABLE ROW FIXED ROW

Plate support beam with diaphragm

B-B A-A
B
Blende
A A
Velocity characteristic without diaphragm

Velocity characteristic with diaphragm

Pressure loss of diaphragm

120
110 0,03 m
100 0,04 m
90 0,05 m
pressure loss [mbar]
80 0,06 m
70 0,07 m
60 0,08 m
50 0,11 m
40
30
20
10
0
0 100 200 300 400 500 600
Flow [m³/h]
REPOL
The Hydraulic Drive

Principle of drive
position sensor
Return stroke Pre stroke

M
Drive axle
position sensor
Hydraulic Drive, Support of Drive Girder
Guide roller
Seal
Supporting
roller
REPOL
The Housing
Cooling of the Bullnose

Bullnose with Shaped Bricks
New After 13 months of operation

Cooler roof
REPOL
The Hammer Crusher

Hammer crusher
The End

Design Clinker Cooler

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Design Clinker Cooler

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Page 1 SilzR 24 Jun 2005 S:\Team\Training\SONGIFA\021-3-Klinkerkühler\ClinkerCoolerREPOL1.

REPOL with end crusher

General Design of REPOL

Grate driving beam

Grate Gußkörper: 1.4825, Verschleißplatte: 1.5415 + Eurodur 2000

The Static Grate

The static grate

Aeration of the static grate

Static grate with nozzles

The static grate - Air blast nozzles

The static grate - Plate fixation

The static grate

The Moving Grate

General Design of REPOL

Grate driving beam

Bearing of oscillating frame

fixed Support beam

Sealing of partition wall

• Specific area load: max. 50 tpd/m²

• Installed cooling air: up to 2.3 Nm³/kgCli

Kiln capacity related to grate width of REPOL

10000 number of strokes: 15 1/min

Clinker End Temperature as Function of

The Jet Stream Plate

The JET STREAM Plate

The JET STREAM Plate - principle drawing

Good cooling of the plate

The JET STREAM Plate - Wear Test

Wear rates of the different materials

0,41 0,35 0,25

Jetstream plate - service life related to wear

Jetstream plate - service life related to wear

service life dep. on wear cumulated service life

Operational results of the Jetstream plates

Codeword Year of Clinker Cooler Service Expected

Schwenk KG, 1996 5.25 12 440.000 > 600.000

Jetring plates: 150,000 to 250.000 t / plate

* Parameter for numbers of strokes / time.

Grate riddlings in the case of Jetstream plates

Customer / Codeword Grate riddlings

Measuring results referred to

Schwenk KG, Bernburg 1200 kg of clinker dust / 100 m²

Milke Zement, Geseke 900 kg of clinker dust / 100 m² 24 h

Fastening of the grate plate

Optimized lateral guidance of the plate

REPOL, Details of grate

Seal between the grate plates

REPOL, Details of grate

REPOL, Details of grate

REPOL, Details of grate

REPOL, Details of grate

REPOL, Details of grate

Aeration system for a REPOL Cooler

Grate 1 STATIC GRATE

Cooling air fan number : 9

Specific load : 45 - 50 t/d.m²

Specific volume : 2.1 Nm3/kg-ck

Optimized aeration and sealing air ratio 7:1

FIXED ROW MOVABLE ROW FIXED ROW

Plate support beam with diaphragm

Velocity characteristic without diaphragm

Velocity characteristic with diaphragm

Pressure loss of diaphragm

The Hydraulic Drive