WE HAVE A PROLEM IN OUR COOLER (CLAUDIUS PETERS).

WE ARE FREQUENTLY FACING THAT PROBLEM, THE

PROBLEM IS , AT THE KILN DISCHARGE END OF GRATE COOLER MORE RED HOT CLINKER IS LEAKING TO THE
HOPPER. DURIING SHUT DOWN WE ARE CHECKING THE CONDITION OF GRATE PLATES, AND IN THESE AREAS WE
CAN SEE MORE GRATE PLATES AND SIDE SEALING PLATES ARE BURNING. THIS PROBLEM IS FREQUENTLY
HAPPENING AND UPTO NOW WE COULDNT DETECT THE ACTUAL PROBLEM. THE CLINKER
LEAKAGE IS SAME LIKE WATER FALL. DUE TO THIS WE HAVE TO STOP OUR KILN ONCE IN A MONTH.

SO, IF YOU HAVE AN IDEA ABOUT THIS PROBLEM PLEASE LET ME KNOW.

I found this passage in a book called "Clinker Coolers" by Hans E. Stench (Chapter 3.8, p494-495), which may be
helpful to you; -

"The fact that especially large diameter type kilns tend to discharge fine clinker on the kiln’s load side and coarse
clinker on the opposite side can make it difficult to get good clinker distribution. Due to the high air resistance of a
fine clinker bed, “red rivers” often are inevitable. Studies show that “red rivers” can cause a variation in air
distribution of 1:6 between the fine and coarse clinker side and can even cause clogging of the bed. Therefore,
grate plates sometimes become red hot in places. “Red rivers” also cause an increase in clinker discharge
temperature. Measures for improving the clinker distribution should start at the cooler inlet. Where “snowmen”
cause poor clinker distribution, the cooler back and sidewalls can be kept clean with the help of compressed air
cannons. Some improvements are possible by slowing down the movement of the fine clinker bed and diverting
more fine clinker to the coarse cooler side, thus increasing the overall clinker bed resistance which pushes more air
through the fine clinker bed. This diversion can be done by using wedge-type grates with 125-mm or 200-mm high
faces. The grates are arranged in a checkerboard pattern as shown in Figure 3.8.17. An often-successful way to
improve the situation is to narrow the cooler grate area on the fine clinker side. By doing so, the clinker bed
becomes narrower and often eliminates a severe segregation of fine and coarse clinker. It is recommended that
the cooler inlet grate width not exceed 2.5 m for kiln capacities up to 2,500 metric tons per day of clinker. Figure
3.8.17 shows that some air holes in corner grates are blanked off. Corner areas often have a low clinker load which
results in heavy air channeling and bypassing the clinker load. Blanked off air holes ensure that cooling air is
diverted into the clinker load. When severe “red river” conditions exist and loss of cooler grates are experienced,
“Ondufin” grates can be applied. The grates have cooling fins on the underside which increase the cooling surface.
The grates stay cooler and last longer. In addition, if a grate is burned through, the fins prevent large clinker
spillages for a considerable time. When “red river” conditions in a pre-1990’s style cooler is extremely severe,
compartments can be divided into two sections. Two cooling fans, one on each cooler side, assure that both grate
areas, the fine and the coarse side, receive the proper amount of air. Or, the design can be upgraded to one with
air beams or mechanical air flow regulators for small groups of grates. Some suppliers, borrowing from the air
beam technology, offer a grate plate design for pre-

1990’s coolers where the air has to travel through a labyrinth in the grate – first up, then down – before exiting
into the clinker bed. This provides an effective clinker seal that reduces the amount of clinker falling through the
grate plates to the under-grate compartment. Increasing the clinker bed thickness generally improves the overall
clinker distribution and heat transfer. Good results have been experienced with clinker beds up to 1 meter deep. In
addition, lower grate speed has had a positive effect upon grate wear rates. High under grate pressures and
airflows adversely affect the conveying action of a reciprocating grate. High air pressures can reduce the friction
between the clinker and the grate, which in turn can speed up the movement of the clinker toward the cooler
discharge. The air, which expands as it rises in the bed, causes the clinker at the surface to be fluidized. The result
might be that clinker flows down the slope if the grate area is inclined or that the clinker can only be moved with
extremely high reciprocating speed on horizontal type coolers. To prevent clinker from flowing forward, the single
grate surface should be at least horizontal. Experience has shown that the best results can be attained with a
maximum of 4.7 to 5.5 kPa under grate pressures in horizontal and 3-degree inclined coolers.
AIR DISTRIBUTION VERSUS OVERALL COOLER EFFICIENCY
Optimized air distribution also improves the overall thermal cooler efficiency and prevents damage to grates due
to overheating. To achieve this goal, predefined amounts of cooling air need to be established for every cooler
compartment. Coolers with air beams or mechanical air flow regulators can refine the air distribution even more to
sections of grate plates or to individual plates. The optimization of airflow is especially important for the heat
recuperating zone. Too high amounts of air do not give maximum secondary air temperature. Too low amounts of
air elevate the clinker discharge temperature. Too high amounts of air also promote fluidization of the clinker. As
the finer clinker particles are likely to be entrained in the locally intensified air flow, high amounts of dust cycles
between kiln and cooler are likely. Dust particles might also be picked up from highly fluidized areas and
concentrate in others, thereby intensifying any “red rivers.” Extremely high airflows also promote heavy air
channeling, giving a poor heat exchange for a grate cooler of 1970’s to mid-1990’s vintage.

It is recommended that maximum airflow not exceed approximately 140 normal cubic meters per minute per
square meter of cooler grate area. Figure 3.8.18 shows a chart of optimized cooling air distribution for a typical
eight-compartment reciprocating grate cooler. The first five compartments (including quench compartment)
supply secondary air and tertiary air if applicable; compartments #5 through #8 cool the clinker to a final
temperature of approximately 100°C. Lowering the clinker discharge temperature further with more air increases
the electrical power consumption considerably. Depending upon the total amount of cooling air used, the power
consumption for the cooling fans can run between 3 and 8 kWh/ton of clinker, plus up to 4 kilowatt-hours for
venting. coolers, and 2.0 to 2.5 kPa in old 10 degree inclined coolers."

This is not a surprise to hear material spillage in the 2nd generation grate coolers. When the grate plates are
installed/ commissioned the minimum gap between plates are measured and the correction is done accordingly.
As days move the gap between the plates and side seals starts to increase and after some time they open up so
badly to allow red hot material spillage into the bottom hoppers (loss in thermal energy when the red hot clinker is
not shredding the heat in the recuperation region).

Now in our modern 4th generation clinker coolers from Fons Technology International, we are offering moving
lanes of grate plates along the length. These coolers come in modular type so the same module with different
cooler sizes shall support 300 TPD - 13000 TPD with less downtime for upgrade, providing 75 -80% recuperation
efficiency. Hydraulic drive increases the availability and the lane technology allows mixing of fine and coarse
clinker by varying the stroke length of the individual lanes across the width of the coolers.

Apart from this Iso Kinetic Inlet (static inlet) is offered to avoid snowman and minimize compressed air
consumption in the inlet. With the snowman free inlet, the secondary and tertiary air temperatures are achieved
to the best level.

If you need mor information, please contact us jayaram@fons.dk or refer www.fonstechnology.com/

http://video.flsmidth.com/flsmidth-online-course-basic
http://video.flsmidth.com/virtual-reality-tour-for-flsmidth
http://video.flsmidth.com/jetflex-burner
http://video.flsmidth.com/kilnloq-gas-analysis-system
http://video.flsmidth.com/flsmidth-advanced-filtration

22-04-2020

DAILY REPORT-KR

A-WORKED HOURS: 8.00 am - 6.00 pm Home office

 We have conference call on MT and discussed on ACL wah upcoming refractory bricks
order for ANKRAL-Q1 18m lining
 Discussed on WHR local contract
 Discussed on Attock cement IK&N cooler project for all 03 lines
 Offer for the grinding media of BCL plant

21-04-2020

DAILY REPORT-KR

A-WORKED HOURS: 8.00 am - 6.00 pm Home office

 We have discussed on Dalta Fons cooler on conference call

 Askari cement WHR matter
 I have studied IK&N cooler, FLS cross bar cooler technology and operation
 Contacted at Pioneer cement for new line update
 Registered on Webinar for online training on turbine