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Fons Technology International

1. General Information

Date: dd/mm/yyyy
Contact Person:
E-mail:
Telephone: Cell phone:

2. Cement Plant General Information

Plant Name:
Address:
City: Country: Zip Code:

3. Cement Plant General Data

Clinker Production Capacity: tpd

Rotary Kiln Dimensions: Kiln Line Nos:
Site Elevation (meters above sea level): m
Plant Working Hours per Annum:

4. Climatic Conditions

4.1 Temperature

Annual Average Temperature: °C

Absolute Maximum: °C Absolute Min °C

4.2 Relative Humidity

Annual Average Humidity:

Annual Average Maximum: Annual Avg. Min:

4.3 Rain Fall

Average per Year: Maximum:

4.4 Wind

Average Speed: Maximum Speed:

4.5 Seismic Conditions

Seismic Zone:

5.Cooler Area Power

Main Incoming Voltage: Medium Voltage:

Low Voltage: Frequency:
Cost of Power Rs/ Kw
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Fons Technology International

6. Kiln Specific Information

Type of kiln: Long wet process Preheater

Long dry process precalciner

Type of fuel: Petcoke t/h

Natural gas m3/h
Heavy fuel oil m3/h
Coal t/h
Waste t/h
Other, pls explain:
Cost of fuel Rs/ Ton of fuel

Total fuel consumption: kcal / kg

Kiln bypass ratio: %
Primary air to kiln %
Primary air to calciner %
Oxygen (after kiln) %

7. Clinker Cooler

7.1 Clinker Cooler Specific Information

Cooler Make: Year Built:

Cooler Model:
Clinker Cooler Actual Production: tpd
Clinker Cooler Production Required after Modification: tpd

Available Grate Area: m2

Aerated Grate Area: m2
Clinker Size Distribution: %< 10 mm %< 25 mm
Raw Meal Feed Rate:
Liter Weight of Clinker: g/l

7.2 Existing Fans Operation

IF VFD then
Actual operation Design capacity Motor KW
[m3/s] [mmH2O] [m3/s] [mmH2O] [kW]
Cooling fan 1:
Cooling fan 2:
Cooling fan 3:
Cooling fan 4:
Cooling fan 5:
Cooling fan 6:
Cooling fan 7:
Cooling fan 8:
Cooling fan 9:
Cooling fan 10:
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7.3 Existing Cooler vent ESP Details

Cooler vent ESP Details Design Operating Dust handling Drag Chain Nos
Gas flow m³/s Capacity of drag chain TPH
Temperature °C Nos of ESP hoppers
Gas density kg/m³ Capacity of rotary air lock TPH
Dust load g/m³
Mechanical design temperature

7.4 Existing Cooler vent ESP fan Details

Cooler vent ESP Details Design Operating

Gas flow m³/s
Temperature °C
Gas density kg/m³
Dust load g/m³
Mechanical design temperature

7.5Cooler Process Information (this section should be filled regarding to below picture)

(A) Secondary Air

Flow [Nm3/s]: Temperature [°C]:

(B) Tertiary Air

Flow [Nm3/s]: Temperature [°C]:

(C) Middle Air

Flow [Nm3/s]: Temperature [°C]:

(D) Exhaust Air

Flow [Nm3/s]: Temperature [°C]:

(E) Water Injection [kg water/h]:

(F) Total Cooling Air

Flow [Nm3/s]: Temperature [°C]:

(G) Clinker Exit Temperature [°C]:

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Fons Technology International

7.6 Clinker Crusher

Make: Year Built: Model:

8. Additional Information Required - Please Submit to Fons Technology International

a) General arrangement drawing of Cooler

b) General arrangement drawings of the cooler building, showing cooler fan locations and ducting.
c) Location of the kiln pier adjacent to the cooler.
d) Grate line diagram showing the configuration of the grate line.
e) Grate line layout – dimensional
f) Drawing showing location of the partition plates
g) Drawing showing the height above the grate line in the throat area.
h) Drive arrangement drawings, if drive needs modification ( if half cooler modification)
i) Cooler Fan GA and Foundation Drawings, if existing fans foundation resuing feasibilty to be checked.
j) Drawings showing the location of the movable frame with respect to the top of stationary side frame.
k) Drawings of stationary side frame, showing the column locations, duct openings, access doors.
l) Drawings of movable frame
m) Pyroprocess General Layout / A recent Heat Balance (if available)

9. Objective
Please explain/comment the reason for the modification of the cooler in your required order as 1 being top priority
Fuel Saving 1
Capacity Increase 2
Clinker temperature reduction 3
Maintenance cost reduction 4
Elimination of red river 5
Elimination of clinker fall through 6
Higher secondary air 7
Others 8