Clinker Cooling- Making the most out of your energy

Transcription

1 Clinker Cooling- Making the most out of your energy VDMA May 2013 Stephan Oehme Director Sales and Technology

2 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

3 The Claudius Peters Group Claudius Peters Technologies S.A.S. Claudius Peters Projects GmbH Claudius Peters Americas Inc. Claudius Peters (Ibérica) S.A. Claudius Peters (Románia) SRL Claudius Peters (India) Pvt. Ltd. Claudius Peters (UK) Ltd. Claudius Peters (Italiana) srl. Claudius Peters (Asia Pacific) PTE. LTD. Claudius Peters (China) Ltd. Hong Kong Claudius Peters (China) Ltd. Beijing Claudius Peters do Brasil Ltda.

4 Cement production flow chart Raw material grinding Raw material stacker/reclaimer conveying Blending silo Precalcining Rotary kiln Clinker cooler Coal storage grinding & firing Clinker storage Cement grinding Cement storage Packing palletising truck loading Mixing Pneumatic Conveying

5 Claudius Peters Experts in Clinker Cooling Successful figures worldwide HE-Module installations since 1994 Cooler Conversions coolers since 1950 for more than 60 Years

6 CP Clinker Cooler Evolution Claudius Peters Originator Hydraulic Drive 1976 Roller Crusher tpd Cooler 1992 Compact Swing Support 1998 ETA Cooler 2004

7 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

8 High Efficiency Module (Static Inlet) Protection Static layer protects the grate plates of the HE Module

9 Principle of Movement Movement pattern example with 4 lanes Forward stroke Step Step 2 Backward sequence Step 3 Step 4 Worldwide patents applied / pending

10 Self-Protective Design against Wear and Heat Hardfacing Clinker bed Wear protection 93 % protected by simple stones remaining ribs hardfaced

11 Holcim Siggenthal after 7 years of Operation Only paint is off the cooler is ready for production

12 Self Protection Summary 1: HE-Module: HEM-Plates are protected by a static clinker layer 2: Aerated Lanes: 93% of the surface is covered with simple stones protection against mechanical wear protection against heat damage 3: Stroke length / Cycles: Long stroke length causes slow movement which reduces wear

13 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

14 Segregation Effects due to Kiln Rotation Coarse clinker side, low pressure drop Fine clinker side, high pressure drop Tendency to develop a red river on the coarse and fine side Coarse clinker Fine clinker

15 Clinker Cooling Curve Big influence at the front of the cooler Small influence at the end of the cooler

16 Red River of Traditional Cooler Typical Grate Cooler Troubles: Hot fine clinker reaches end of the cooler High wear on grate plates Hot air flows in exhaust air duct Clinker is not cold at the end of the cooler Recuperation is not optimum. NO Grate cooler can influence the clinker flow over the cooler width! YES ETA CAN!

17 Aeration Scheme HEM 1,2m 1,4 m 2,2m 2,2m CSA 3,3 / 4,4 m CSA Recuperation zone Cooling zone 1. High Efficiency Module (HEM) 2. Controlled Side Aeration (CSA) 3. Individual Stroke Length

18 Process Optimized Aeration 1: HE-Module (HEM): Small aeration fields ensure precise and adjustable aeration in the drop zone 2: Aeration Chambers: Small aeration chambers at the cooler front, bigger chambers further down the cooler; >> corresponds with the clinker cooling curve 3: Chamber Side Aeration (CSA): Longitudinal Chambers Left and Right to prevent red river 4: Individual Stroke length: Shorter stroke length on the sides to prevent red river

19 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

20 Modular Design Essential design features: fully modular constructed standard sizes flexible module arrangement for existing plants pre-assembled modules to site

21 Semi-Modular Design HE-Module Grate plates horse shoe refractory air distribution with measuring devices lane units With sealings hydraulic drive HE-Module steel work roller units with cross traverse partition walls CP supply Possible local or customer supply lower side walls

22 Sample of Revamping of an Existing Grate Cooler Type Fuller

23 Erection of ETA Units ETA Units are brought in one after the other

24 Overview Unit vs. Modular vs. Semi-Modular Unit Modular Semi-Modular Portion CS / local Low Lowest High Pre-manufactured Yes Yes No Key components CPP CPP CPP Steel work / lower part Existing CPP Local / Customer Quality control 100% CPP 100% CPP Partial Local Assembly Shortest Short Extended Handling / transport cost Medium Higher Lower

25 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

26 Comparison ETA versus Grate cooler Modern ETA Cooler Traditional Grate cooler Bed height 800 mm 600 mm Retention 45 t/d/m² 35,8 min 26,9 min Power consumption 6,76 kwh/t clinker 5,9 kwh/t clinker Cooler efficiency 77,6% 74,1% Clinker bed = Power consumption = Cooler efficiency

27 Comparison ETA versus Grate cooler

28 Comparison ETA versus Grate cooler

29 Introduction ETA Cooler 1. CP Clinker Coolers 2. ETA Cooler Self Protected design Process Optimised Aeration 3. Delivery 4. Comparison ETA vs. Grate Cooler 5. References

30 Overview ETA References ETA Cooler sold 56 Replacing conventional cooler 19 Replacing satellite cooler 4 Behind wet kilns 3 Cooler in backward design 2 ETA Cooler as stage cooler 17 ETA Cooler as a base for waste heat recovery 16 ETA Cooler in operation 42 Min. Capacity 700 t/d Max. Capacity t/d

31 Ref 46 Holcim Untervaz ETA 856 / 1950 (2100) t/d ETA Highest Energy Recovery Lowest Performance ( during Maintenance official 18 days performance evaluation ) Design Operation Capacity [t/d] Clinker Outlet [ C above suction temp.] Cooling Air Amount [Nm³/kg cl.] 1,670 1,482 Cooler Efficiency [%] 74,0 75,8 Spec. el. power consumption cooling air fans [kwh/t] 5,3 4,39 31

32 Thank you for your kind attention CP Headoffice & subsidiaries