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    Cooler

    Uploaded by

    tricky777
    The document provides design criteria and operational parameters for cooler systems in cement plants. It discusses optimal cooler width, loading, air quantities, velocities, and offsets from the kiln center based on production levels. It also describes methods for calculating cooler efficiency and factors that affect efficiency like clinker properties, distribution, air distribution, temperature, and bed height. Prevention of issues like snowman formation and side wall damage are also covered.

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    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd

    Cooler

    Uploaded by

    tricky777
    1K views19 pages
    The document provides design criteria and operational parameters for cooler systems in cement plants. It discusses optimal cooler width, loading, air quantities, velocities, and offsets from the kiln center based on production levels. It also describes methods for calculating cooler efficiency and factors that affect efficiency like clinker properties, distribution, air distribution, temperature, and bed height. Prevention of issues like snowman formation and side wall damage are also covered.

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    cooler in cment industry

    Original Title

    3. Cooler

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    The document provides design criteria and operational parameters for cooler systems in cement plants. It discusses optimal cooler width, loading, air quantities, velocities, and offsets from the kiln center based on production levels. It also describes methods for calculating cooler efficiency and factors that affect efficiency like clinker properties, distribution, air distribution, temperature, and bed height. Prevention of issues like snowman formation and side wall damage are also covered.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd
    Download as pps, pdf, or txt
    1K views19 pages

    Cooler

    Uploaded by

    tricky777
    The document provides design criteria and operational parameters for cooler systems in cement plants. It discusses optimal cooler width, loading, air quantities, velocities, and offsets from the kiln center based on production levels. It also describes methods for calculating cooler efficiency and factors that affect efficiency like clinker properties, distribution, air distribution, temperature, and bed height. Prevention of issues like snowman formation and side wall damage are also covered.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPS, PDF, TXT or read online from Scribd
    Download as pps, pdf, or txt
    of 19

    DESIGN CRITERIA OF COOLER

    Section Cooler width, m Cooler loading, tpd /m2 Cooling air quantity, Nm3/kg Parameter 0.6 * Kiln diameter 55 65 1.85 1.90 ; > 2.3 air quantity, recuperation efficiency of cooler remains flat, i.e. further clinker cooling not possible 1.0 1.2

    Vent air quantity, Nm3/kg

    DESIGN CRITERIA OF COOLER


    Section Kiln hood gas velocity (m/sec) TA take off velocity (m/sec) Parameter 3.5 to 4.0, < 5 6 to 7

    Cooler off center


    w.r.f to Kiln center (mm) < 1500 tpd clinker production 1500 to 2500 tpd production 300 400 to 450

    > 2500 tpd production

    550 to 600

    COOLER OPERATION
    A. Cooler Efficiency
    = Heat Recovered Heat Input x 100%

    = Heat with SA + TA + Coal Mill Air x 100% Heat with (Clinker + Cooling air)

    Difficulty in determination of efficiency Secondary air temperature Secondary air quantity Temperature of clinker entry to cooler

    COOLER OPERATION
    OR

    B. Cooler Efficiency
    = Heat Input Heat Loss Heat Input Heat loss = x 100

    heat with clinker + heat with cooler vent air

    Here again temperature of clinker entry to cooler is difficult to determine.

    COOLER EFFICIENCY DEPEND ON


    1. Clinker Granulometry 2. Clinker Distribution 3. Cooling Air Quantity 4. Cooling Air Distribution 5. Clinker Inlet Temperature 6. Bed Height / Compartment Pressure

    CLINKER GRANULOMETRY

    Depending on the size of the clinker, resistance to fan flow varies Coarse clinker (bigger size) has low resistance & more air flow to pass through Finer clinker has packed bed, more resistance & thereby decreases air flow through them It is always difficult to make the clinker bed with uniform clinker granulometry

    CLINKER DISTRIBUTION

    Fine & coarse clinker fall at different position on projectile principle More the Kiln rpm, more is the separation of fall position of fines & coarse More wider space at cooler fall point, more difficult to clinker distribution Cooler width should not be more than 60% of Kiln dia. Horse shoe arrangement to be provided at the cooler inlet part for better distribution

    TYPICAL HOT SHOE AND DEAD GRATE PLATE ARRANGEMENT

    COOLING AIR QUANTITY

    For cooling clinker 65C above ambient, cooling air quantity is required 2.3 Nm3/kg clinker or 3 kg/kg clinker. Lowering down the cooling air quantity leads to higher clinker outgoing temperature & cooler vent temperature. Cooler with static grate of cooling air quantity 1.6 1.8 Nm3/kg clinker have higher vent air temperature & generally clinker outgoing temperature 105 110C above ambient.

    COOLING AIR DISTRIBUTION

    Recuperation efficiency of the cooler depends on how cooling air distribution is made. Total hot air for combustion (SA + TA) i.e. 0.80 0.85 Nm3/kg clinker has to be distributed before NULL point of cooler. Generally for good designed cooler, the null point is at the end of the 3rd compartment.

    DESIGN CRITERIA OF COOLER


    COOLING AIR LOADING IN DIFFERENT COMPARTMENT

    Compartment Cooling Air Loading Nos. (Nm3/min/m2) 1st Fan 115 2nd Fan 105 3rd Fan 95 4th Fan 80 5th Fan 70 6th Fan 55 7th Fan 45 8th Fan 30/35

    0.8 0.85 Nm3/kg cl

    Balance = 1.0 1.5 Nm3/kg cl

    COOLING AIR DISTRIBUTION


    Fluidization Velocity Velocity

    115 Air density Nm3/Min/m2

    CLINKER INLET TEMPERATURE


    Higher the clinker temperature, higher is the recuperation efficiency. Faster is the cooling, initial strength of cement will improve because of C3S crystal growth. Slow cooling has advantage of 28 days strength because of C2S crystal growth. Hence it is a preferable to have a cooling zone inside the Kiln so that fall of clinker temperature on cooler is approx. 1300 1350C & not 1450C.

    BED HEIGHT / COMPARTMENT PRESSURE


    Higher the bed height, better is the recuperation efficiency. Bed height = (Compartment fan pressure 100) mm Fan has to be selected for a particular compartment with reference to 10% higher in volume and 25% higher in pressure. Fan has to be selected for a Stiff curve & not a Flat curve nature.

    PREVENTION OF SNOWMAN FORMATION


    Cooling air loading in the compartment as per designed norm. Cooler back wall preferably 70 inclined with reference to cooler grate towards kiln side or 110 with respect to cooler grate towards grate movement. As working point of Kiln on hot condition 300 mm with reference to cooler back wall, clinker will fall 300 mm away from from back wall when back wall is vertical and clinker can not be spread uniformly over the width of the grate.

    PREVENTION OF SNOWMAN FORMATION

    If the back wall is constructed at 70


    starting from 600 mm away of vertical wall, the clinker can be spread uniformly.

    Without inclined wall & using air blasters is a prevention to snow man formation

    but not a cure.

    PREVENTION OF SIDE WALL DAMAGE

    At least upto 4th compartment grate plate, dead grate plates to be installed on both sides of the cooler to protect the side wall & cooler side frame. Compartment hopper bottom should have motorised double flap dampers with level sensors to prevent air leakages. Partition plates between compartments should be perfectly maintained to prevent air leakage.

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