CLINKER COOLER

CLINKER COOLERReduce clinker temperature from approx. 1400 oC to approx 100 ~ 200 oC The heat of the incoming clinker is recuperated in the secondary air of KilnAn efficiency of incoming clinker heat usually lies within 65 ~ 75%

Clinker Cooler TypeGrate CoolerCross flow heat exchange through clinker bed with cold airGrate movement : reciprocating; consisting of movable row (reciprocating) & fixed rowGrate can either be horizontal or inclined (3o)Occurrence of waste air requires additional equipment for dedustingCapacities of up to 10,000 tpdRotary CoolerSeparate tube with separate driveHeat transferred by internal equipment (lifters)No waste airCapacities of up to 4,500 tpd maxPlanetary CoolerSet of tubes fixed to the kiln no separate drive requiredHeat transferred by internal equipment (lifters)No waste airNot suitable for separate tertiary air duct precalcining systemCapacities of up to 5,000 tpd

INCLINED COOLER (Claudius Peters)

PYROSTEP GRATE COOLER (KHD)

MAINTENANCE for GRATE COOLERDriving Mechanism :MechanicalHydraulicalGrate Frame MechanismDriving Support (incl. Wheel, rail, bearing, sealing plate)Driven Support (incl. Wheel, rail, bearing, guide wheel)Ceiling Chamber : air leakagePartition plateExpansion jointGrate Plate & Air BeamGrate plate worn out, bolts looseness, side plateAir beam: deform, bolts loosenessDischarge Hopper & Flap DamperDrag Chain Mechanism (e.g : chain condition, bearing, coupling)Cooling Fan Mechanism (e.g : bearing, impeller, suction cone, coupling)Clinker Crusher (e.g : grizly bar, hammer, disc, bearing, driving)Casing, castable, bullnose

DRIVING MECHANISMMechanicalHydraulical

DRIVING SUPPORT FRAME

DRIVEN SUPPORT FRAME

GRATE PALTE & AIR BEAM

Omega-plate with wear protectionThrust area and thrust edge made out of extreme wear resistant compound material with heat resistant basic material with hardness of 63 HRc

Discharge Hopper & Flap Damper

Clinker Crusher

Bull Nose Cooler

Bull Nose Cooler

Bull Nose Cooler

Smith Fuller Cross Bar Cooler

Air Distribution Plate with Mechanical Flow Regulator

Cross Bar InstallationDistribution of air is optimized for all mode of operationMaximum availability and minimum maintenance (no movable grate plate, only reciprocating cross bar) No fall through of clinker & no undergrate conveying system is requiredStatic clinker layer protects air distribution plates against wear and heat, so plates will remain in service for a long time

Reciprocating Cross Bar and Stationary Clinker Layer

Rotary Cooler

Inside Rotary Cooler

Lifter Rotary Cooler

Planetary Cooler

Maintenance for Planetary CoolerInlet Cooler :Cracking at neck areaInlet segment conditionCooler Elbow :Elbow ConditionExpansion jointCooler Tube, Support and Outlet Casing :Fixation condition (fixed side and loose side)Cracking and wearing ConditionInternal Part : Breaker, Scattering and Lifter CoolerClinker Crusher (e.g : grizly bar, hammer, disc, bearing, driving)

Zone 1Breaking zoneIncrease specific surface of clinkerZone 2, 3 & 4Breaking up effect of the clinkerand segregation capabilityZone 5Maximum Lifting areaLow secondary air speed, creates low dragging kinetic energy against fine clinker

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