Clinker Cooler

1400 °C

Clinker
Temp.

100-200 °C
Types
of
coolers
Grate Cooler
Planetary Cooler
Rotary Cooler
 Grate Cooler
Cross flow heat exchange through clinker bed with
cold air

Reciprocating grate type

Occurrence of waste air requires additional equipment

for de-dusting

Capacities of up to 10,000 t/d

Alternative forms with two stage cooling and air re-

circulation are possible

Travelling grate type : poor clinker distribution &

movement on the grate and therefore lower efficiency
 Rotary Cooler

Separate tube with separate drive

Internal heat transfer equipment (lifters)

No waste air

Capacities of up to 4500 t/d maximum, preferably

up to 2000 t/d
 Planetary Cooler
Set of tube fixed to the kiln, therefore no
separate drive required

Internal heat transfer equipment (lifters)

No waste air

Not suitable for AS pre-calcining systems

Capacities of up to 5000 t/d maximum, preferably

up to 3500 t/d
 Main function of clinker cooler

Recuperate the clinker heat by heating up the

combustion air

Maintain a minimum cooling velocity in order

to avoid unfavorable mineralogical clinker
phases and crystal size

No waste air
 Working principle of coolers

1- Grate Cooler

The clinker forms a

bed which is
transported along
the grate by
different
mechanisms
 Working principle of coolers

Part of air can

be used as
combustion air
The cooling air
is blown from
below the grate
by fans & pass
through the
clinker bed in
cross current
 Working principle of coolers

2- Tube Cooler

The material & the

cooling air are led
in counter current
through one or
more slightly
inclined rotating
tubes
 Working principle of coolers

2- Tube Cooler

Special lifters are

installed which
increase the active
heat transfer area
between clinker
and cooling air
 Working principle of coolers

3- Shaft Cooler

An ideal counter
current heat
exchange takes
place between
the clinker
moving down by
gravity and the
rising cooling air.
 Thermal cooler
efficiency
η = total heat content of the clinker leaving the kiln
the heat of combustion air

Cooler efficiency depends on :

The required combustion air of the kiln system

Coolers comparison based on :

- Identical heat consumption

- Same excess air factor

- Same primary air ratio

Rotary Cooler
 Design of Rotary Cooler

Diameter of the cooler is similar to that of a

corresponding suspension preheater kiln.

Rotating speed is in the same range as for

the kiln (max. 3 rpm)

The length to diameter is approximately = 10

The inclination is comparatively high

“in the order of 5%”
Rotary Cooler layout
Internals
of
Rotary
Coolers
 Advantages
Simplicity of cooler design, robust piece of equipment.
No special mechanical problems (at least not more
problems than on a rotary kiln).

No control loop

Easy commissioning

No waste air , therefore no dedusting equipment required

Electrical energy consumption is approx. 5 kwh/t lower than

for a grate cooler

Rotational speed can be adjusted, therefore upset kiln

conditions can be handled more easily than planetary cooler.

Suitable for pre-calcining system having a separate tertiary air

duct (extraction of hot air is possible)..
 Disadvantages
Little experience available with large coolers (above 2000 t/d)

Formation of buildups (snowman) in the inlet chute.

A water-cooled chute or a dislodging device is required in

such a case .

Clinker outlet temperatures tend to be high and therefore

water injection is usually require & Due to large falling height
wear protection in the tube must be reinforced (compared to a
planetary cooler) .

High kiln foundations are required.

Cooler inlet seal can contribute to additional false air inlet

Planetary Cooler
Planetary Cooler
Temperature Profile of Planetary cooler
 Design Feature of Rotary Cooler

Shell extension

Fixation of cooling tubes

Design of cooler supports

Cooler length

Inlet openings
 Heat Transfer and Efficiency

The heat transfer in a planetary cooler is based on a

counter heat exchange between clinker and cooling
air.
 Items influence the efficiency

The clinker must be brought in an intensive contact

with the cooling air

The quantity of available cooling air affects the

efficiency

The efficiency is not only determined by the machine

itself, but also by the amount of cooling air.

The granulometry of the clinker affects the cooling

efficiency
 Rough guideline for the Heat Balance

Heat input by clinker 1200oC 100%

Heat output
By secondary air 750oC 68%

By shell losses 22%

By clinker outlet 170oC 10%

Specific Load

P t
=
n x D xL
1.5 = m2.5 xd
Where :
P = Clinker production in t/24 h
n = Number of coolers tubes
L = Length of cooler tubes in m
D = Cooler tube diameter in m
d = Satellite tube diameter in m
To avoid dust circulation

P
< 70 t/m2
n x D2 x π/4
The efficiency depends on :

Design and condition of the internal heat

transfer equipment

Operating conditions
Enhanced Cooling
Possibilities of
water cooling
External Water Spray

Internal Water Spray

 Advantages

Simplicity in design and operation. No control loops are

required.

No Exhaust air is produced and therefore de-dusting is

required.

Specific power consumption is by 6 Kwh /t lower than with

grate cooler and by approximately 2 Kwh /t more than with
rotary cooler.

commissioning is easy.
 Disadvantages
Virtually no control of cooler operation is possible ( critical in case of
material rushes ). There is also no control of the distribution of the
clinker to the individual tubes which may often vary by up to 50 %.

Since there is no exhaust air there is no cooler exhaust air utilization

possible. In cases where this heat could be used for drying purposes
this may become an argument against the planetary cooler.

A planetary cooler might become an important source of noise

emission (depending on the clinker granulometry). If residential areas
are in the vicinity sound protection measures may become necessary

Clinker exit temperatures are comparatively high and call for fully
metallic clinker conveying equipment and adequate cooling in the
cement mill.
 Disadvantages
Spare capacity is relatively little. Cooler is sensitive to overload.

The kiln outlet section is a complicated structure which has to resist

high stresses and temperatures. The protective cast refractory mass
in this area needs close attention. In case of refractory failure the
kiln has to be stopped immediately.

The kiln downtimes tend to be longer because relining work in the

kiln and repair works in the plants have to be performed
simultaneously

The planetary cooler cannot be applied for precalcining kiln Systems

having a separate tertiary air duct because there is no possibility to
extract hot tertiary air. Therefore the planetary cooler is ruled out for
very high kiln capacities (above4000 / 5000 t / d). The necessity of a
bypass may also act against the planetary cooler.
Grate Cooler
 Types of Grate Coolers :

Reciprocating grate cooler

Travelling Grate Cooler

Reciprocating
Grate Cooler
Reciprocating Grate Cooler
Inclined
Cooler
Inclined
Cooler
Design features of modern coolers

Combination Cooler
Important design features of modern grate coolers

Reduced cooler width, in order to operate the cooler with a

thick clinker bed & consequently a good cooling air
distribution and a high heat recuperation

Good sealing of the cooler compartment by means of

discharge hoppers for grate riddlings.

Good accessibility of the spillage drag chain

Fingerless plates supports, allowing a quick replacement of

grate plates from the undergrate chamber
 Important design features of modern grate coolers

Hydraulic drive for each individual grate, with speed range

0 to 25 strokes per minute

Full width clinker beaker

Total cooling air quantity installed in the range of 3 - 3.5

Nm3/kg cli, with fan pressures decreasing from 60-70 mbar
in the first compartment to 20 to 30 mbar in the last one

Possibility of re-circulation of the cooler vent air

Basic Control loops of a grate Cooler Control
Variables of Cooler Control

Grate
Speed

Air Flow
Hood
Draft
 Cooler de-dusting

Kiln in
Normal
Upset
operation
Conditions
Air flow
% 100 up to 150
(actual volume)

Air temperature °C 200 - 250 up to 450

Air dew point °C 5- 20 5-20

Dust load g/Nm3 5-15 25-35

Comparison of de-dusting equipment for clinker coolers
Type of Collector Advantage
 Simple
 Low investment cost
 Low space requirement
Multiclone  Not sensitive to temperature
peaks
 Good experience for may years
 High efficiency
Electrostatic  Low pressure loss
Precipitator  Low operating cost
 Low maintenance cost
 High efficiency
Gravel Bed Filter  Not sensitive to temperature
peaks
 Experience with many units in
operation
 High efficiency
 Relatively low investment cost
Bag Filter
Disadvantage
 Poor efficiency for particles < 20
um
 Efficiency sensitive to gas flow
fluctuation
 Comparatively high pressure loss
 High operating cost
 Bit unit required or use of pulse
generator  high investment cost
 Possibly water injection required
 Highest investment cost
 Highest pressure loss
 High operating cost
 No bags withstanding
temperatures up to 450C  pre-
cooling required
 High pressure loss
 High operating cost
 High maintenance cost
Multiclone

Advantages • Simple
• Low investment cost
• Low space requirement
• Not sensitive to temperature peaks
• Good experience for many years

Disadvantages
• Poor efficiency for particles < 20 micron
• Efficiency sensitive to gas flow flLldu1n1
• Comparatively high pressure loss
• High operating cost
 Type of
Collector Advantage Disadvantage
• Simple
• Low investment • Poor efficiency for
cost particles < 20 micron
• Low space • Efficiency sensitive to
Multiclone requirement gas flow flLldu1n1
• Not sensitive to • Comparatively high
temperature peaks pressure loss
• Good experience • High operating cost
for may years
• High efficiency • Bit unit required or use
• Low pressure loss of pulse generator —*
Electrostatic
• Low operating cost high investment cost
Precipitator
• Low maintenance • Possibly water inj
cost ectioii required
Principle of non ventilating clinker cooler
 Advantages

No dust emission at all

Simple

Low investment cost

Moderate maintenance cost

Moderate operating cost

Heat recovery possible

Extension possible by adding further heat

exchange units
 Disadvantages

Possible wear of fan blades

Maintenance and operating cost higher than

conditional cooler de-dusting system with E.P.
Material temp. & undergrate pressure of grate
cooler
Temp. of secondary air

3250 - ( 347 - Cl ) 
t = ( C)
( X.n )

Notation:
X = Specific heat consumption of the kiln,
kca/kg clinker
n = Number of coolers tubes
Cl = Heat loss of the cooler, kcal/kg clinker
The figures 3250 & 347 are constants
Temp. of secondary air

Assume
Specific heat consumption = 830 kcal/kg

Excess air number of = 1.1

Heat loss of the cooler = 92 kcal/kg clinker

3250 ( 347 - 92 )
t =
( 830 x 1.1 )
 Criteria used for judging the cooler efficiency

1
Cooler Thermal Efficiency:

It is the ratio of the heat reclaimed from the

hot clinker, and utilized in the burning
process, to the total heat content of the
clinker leaving the kiln.

A-B
= *100
A
Cooler Thermal Efficiency:

A-B
= *100
Notation: A
A = Heat content of clinker leaving the kiln
B = Heat losses of clinker cooler
B consists of =
a = Heat loss in cooler exit air
b = Heat loss in clinker leaving cooler
c = Heat loss by radiation
 Criteria used for judging the cooler efficiency

2
The temp. difference between the hot clinker
entering the cooler and the hot secondary air leaving
the cooler
Heat balance of satellite cooler
Coolers thermal efficiency
Range of application

Type of Cooler Optimum Maximum Suitability for AS1) De-dusting

Capacity range3) Capacity (t/d) Pre-calcining Equipment for
(t/d) Systems Waste air Remarks
Required

Reciprocating 7000-3000 10,000 YES YES2)

Grate

Rotary Cooler 500-2000 4,000 YES NO

Planetary 1500-3500 5,000 NO NO

Cooler
 Criteria influence the selection of a cooler

Layout possibilities

Old equipment which can be incorporated in a new

plant

Granulometry of clinker

Noise emission

Possibility to extend capacity in a later stage

Temp. profile in the clinker bed
Clinker transport

The travelling of big chunk or heavy coating from the fixed inlet to
the moving grates is effected by two transport mechanisms

Surface transport

Pneumatic transport