Clinker Cooling- Making the most out of your energy VDMA May 2013 Stephan Oehme Director Sales and Technology
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
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.
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
Claudius Peters Experts in Clinker Cooling Successful figures worldwide 735 228 112 HE-Module installations since 1994 Cooler Conversions coolers since 1950 for more than 60 Years
CP Clinker Cooler Evolution Claudius Peters Originator Hydraulic Drive 1976 Roller Crusher 1978 10.000 tpd Cooler 1992 Compact Swing Support 1998 ETA Cooler 2004
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
High Efficiency Module (Static Inlet) Protection Static layer protects the grate plates of the HE Module
Principle of Movement Movement pattern example with 4 lanes 1 2 3 4 Forward stroke Step 1 1 2 3 4 Step 2 Backward sequence Step 3 Step 4 Worldwide patents applied / pending
Self-Protective Design against Wear and Heat Hardfacing Clinker bed Wear protection 93 % protected by simple stones remaining ribs hardfaced
Holcim Siggenthal after 7 years of Operation Only paint is off the cooler is ready for production
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
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
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
Clinker Cooling Curve Big influence at the front of the cooler Small influence at the end of the cooler
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!
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
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
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
Modular Design Essential design features: fully modular constructed standard sizes flexible module arrangement for existing plants pre-assembled modules to site
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
Sample of Revamping of an Existing Grate Cooler Type Fuller
Erection of ETA Units ETA Units are brought in one after the other
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
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
Comparison ETA versus Grate cooler Modern ETA Cooler Traditional Grate cooler Bed height 800 mm 600 mm Retention Time @ 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
Comparison ETA versus Grate cooler
Comparison ETA versus Grate cooler
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
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 13.000 t/d
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] 1950 1917 Clinker Outlet [ C above suction temp.] 90 52 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
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