Clinker Coolers

Functions • Hot clinker is to be cooled rapidly to secure a phase composition that imparts adequate cementitious properties. maximizing the recovery of heat to secondary and tertiary air. • Heat exchange between clinker and air has to be efficient to ensure proper cooling and. A cooler has to accomplish these tasks efficiently and simultaneously. at the same time. . At the discharge end of the kiln the red hot clinker contains around 1.0 million Btu per short ton thermal energy.

Types of Coolers • • • • • Rotary Coolers Planetary Cooler Shaft Coolers Grate Coolers Cross bar Coolers .

The cooler is inclined at 2. The drive power consumption is about 3.5o and speed of rotation is 3 rpm. .5 kWh/ton.Rotary Coolers • Appears like another rotary kiln after rotary kiln. The clinker temperature after cooling is 200oC to 250oC.

of cement plants came up with 4 stage pre-heaters. .Planetary Cooler • A planetary cooler consists of a no. It requires no excess air to handle. of cooling tubes mounted around the circumference of the kiln shell.5 to 1. making it lowest for any kind of kiln. added to the kiln drive and exhaust fan. no fans or motor and no instrument. The power consumption is only about 0.0 kWh/ton of clinker. when no. • These coolers were popular in 1960 and 1970.

350 oC. but is reduced by water injection.Shaft Coolers • This type of cooler has fairly even size distribution. . The upper part is used as a fluidized bed in order to avoid agglomeration. • Power requirement is 10-12 kWh/ton • With minimum air clinker discharge temperature: 300 oC.

More air is used in the hotter part of grate. Each grate consists certain no. of rows of grate plates. The air to the grates is supplied in various ways through air blower in to compartments under the grates or blown into ducts (called as air beam) connected directly to a limited no. of grates. Normal clinker bed thickness is 600 mm on the grate. • • • • • • • • . which is to be recovered and de-dusted.3 kg/kg of clinker but cooling air fans capacity is designed to allow the introduction of 4. Cooler consists of one or several grate. which may be up to 200 kg/min/m2 and less in the colder part 40 kg/min/m2. Specific load on grate cooler built after 1975 is 30-40 Metric ton per dat per sq. however. Clinker discharge temperature can be achieved up to 80oC. meter grate area. With high air flow and thick layer of clinker.5 kg of air per kg of clinker. which was 20 Metric ton earlier. The grate may be horizontal or inclined. it needs more air. grate -3 etc.Grate Coolers • • Cooling air moves cross current to the direction of clinker movement. Amount of air required is between 2.3 to 3. grate -2. The width of the grate is reduced at the inlet in order to spread the clinker more evenly. These grates can be named as grate-1. it provides uniform bed thickness.

0 kWh/ton clinker cooled. • Grate plates are all stationary. they have been made larger.9 kg air per kg of clinker. • The air is supplied to each plate individually. • The traditional size of grate plates is 30x30 cm.Cross bar Coolers • Developed in 1990s. • Since the plates no longer moves. • The amount of cooling air in reduced from 2.8 to 1. resulting in low power consumption of 4. whereas cross bar cooler plats are 1x1 meter in size. . • Clinker is conveyed by wedge-shaped bars suspended above the grates.

7 160 120 0.8 1.5 70 360 150 12 74 80 NA 7 60 100 NA 4 71 *Thermal Efficiency of the cooler can be given as: .9 0.Typical operational data of different cooler used in dry process kiln Parameters units Planetary Rotary Shaft Grate CrossBar 1.3 0 2.8 Cooling Air requirement Total Cooling air Kg of air/ kg clinker Excess air to vent Kg of air/ kg clinker Clinker Discharge Temperature o After Cooler C o After Cooler with water C kWh/Ton of Power Consumption Clinker % Thermal Efficiency* 1.1 0 1.1 0 1.8 67 220 160 3.

• Clinker bed height Optimization of grate cooler operation: • Optimizing the amount and temperature of Secondary air. • Under grate air pressure • Grate speed for proper movement and retention of clinker in cooler. • Maximizing the uniformity of operation . • Negative pressure in the kiln hood to ensure proper supply of secondary and tertiary air for fuel consumption in kiln and pre-calciner.Control of Grate Coolers • Constant air through the clinker bed in terms of air per unit area of cooler and per unit mass of clinker.

Undesirables • Snow man formation • Red river formation .

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