MHR21924 CMC Chapter CC

Clinker Coolers
Hartmut Meyer
CMS/TPT 12/21924/E (Revision 0, August 2012)
Table of Content
1. INTRODUCTION 2
2. MAIN TASKS OF THE CLINKER COOLER 2
2.1 Overview and definitions of the clinker cooling process 3
3. CLINKER CONDITIONS AT THE DISCHARGE OF THE ROTARY KILN 5
4. OVERVIEW OF CLINKER COOLER TYPES (WORKING PRINCIPLES) 6
4.1 Counter flow coolers (Rotary coolers) 7
4.2 Cross flow coolers (Grate coolers) 8
4.2.1 Travelling grate coolers 9
4.2.2 Reciprocating grate coolers 11
4.2.3 Special cooler applications 22
5. ENERGY FLOWS AND COOLER HEAT BALANCE 23
5.1 Actual cooler efficiency (heat recuperation) 25
5.2 Normalized cooler efficiency: 26
6. GRATE COOLERS: DESIGN AND OPERATION 27
6.1 Main functions and components 27
6.2 Cooling (heat recuperation) zones of grate coolers 28
6.3 The aeration system 30
6.3.1 Configurations of the aeration system 30
6.3.2 Aeration scheme 31
6.3.3 Required fan pressure 33
6.3.4 Air distribution check and clinker cooling curve calculation 34
6.4 Grate drive 37
6.4.1 Check of the clinker bed height 38
6.5 Clinker crusher 39
7. GRATE COOLER CONTROL 41
7.1 Alarms and process interlocks 41
8. TYPICAL PROBLEMS OF CLINKER COOLER 42
9. COOLER LOADS AND SIZING RULES 43
10. TYPICAL OPERATION TARGETS FOR GRATE COOLERS 45
11. THE “THREE GOLDEN RULES OF CLINKER COOLING” 46
12. KEY MESSAGES FOR CLINKER COOLERS 47
1. INTRODUCTION
The clinker cooler is a vital part of the kiln system and has a decisive influence on
the performance of the plant. Three key indicators characterize a good clinker
cooler:
• Maximum heat recuperation

• Effective clinker cooling with minimum cooling air flow
• Unrestricted availability
Reciprocating grate coolers were first introduced by Fuller Company (USA) in 1937.
While its design was continuously being optimized, the grate cooler became the
predominant type in the 1950s. In the late 1960s, the planetary cooler gained
popularity which reached its peak in the 1970s, mainly due to its simplicity. Larger
unit capacities with precalciner technology made the grate cooler the preferred
solution again. A wave of grate cooler developments from the mid 1980's until the
end 1990s was concentrated on improvements of the cooler aeration system. The
recent developments in the last decade were focused on new conveying concepts.
Since cement plants have life cycles of 40 years and more, numerous units of each
cooler type, planetary, rotary or grate cooler of old or new designs, will remain in
operation for many more years.
This paper gives an overview about process technology, requirements, types,

applications, equipment, control and operation of clinker coolers.
2. MAIN TASKS OF THE CLINKER COOLER
After the clinker sintering (burning) process in the rotary kiln the clinker is cooled by
ambient air having direct contact with the clinker particles.
The clinker cooler has two main tasks:

1. Highest possible heat recuperation to reduce the fuel consumption of the kiln
system.
2. Clinker cooling down to 100 to 150°C to enable transport and storage of the
clinker as well as cement grinding.
The copyright for this document and all appendices are reserved by Holcim Group Support Ltd 2/48
2.1 Overview and definitions of the clinker cooling process
Figure 1: Overview of the clinker cooling process
Cooling air is usually ambient air which passes the hot clinker thus being heated up
while cooling the clinker.
Recuperation air is the heated up cooling air returned to the kiln to assure
complete combustion of the fuel.
Recuperation zone is the part of the clinker cooler where the recuperation air is
taken from.
The recuperation air splits into “secondary air” for the rotary kiln and “tertiary air”
going to the precalciner.
To cool down the clinker sufficiently usually the amount of cooling air exceeds the
recuperation air requirement.
Cooler exhaust (waste) air is the remaining part of the heated up cooling air which
is not returned to the kiln as recuperation air. The cooler exhaust air has to be
dedusted.
Cooling zone, also called after-cooling zone, is the part of the clinker cooler where
the exhaust air is taken from.
Primary air is required for the fuel transport and flame control of the burner.
False air is ambient (cold) air entering the system via kiln outlet seal, burner
opening, casing or clinker discharge. It either dilutes recuperation air thus reducing
recuperated heat or adds load to the waste air system of grate coolers.
Combustion air is the required air for complete combustion of the fuel in the kiln
system. Combustion air = recuperation air (secondary and tertiary air) +
primary air + false air on the kiln side
The Kiln ID-fan is sucking the entire combustion air, including the cooler
recuperation air, through the kiln system (see also figure 2).
The Cooler exhaust air fan conveys the remaining heated up cooling air.
Kiln ID-fan and cooler exhaust air fan are the main kiln system fans. They convey
the hot air in opposite direction thus creating a “Zero-point” (hot air split point) in
the clinker cooler.
Figure 2 shows the thermal part of a state of the art kiln system with preheater
tower, precalciner, rotary kiln and clinker cooler.
Kiln ID
Fan
Filter
Fan
Cooler
Dedusting Bag Filter
for Kiln and
Mill Gas
Meal
Dosing
5-stage
Precalciner Suspension
Fuel Dosing
Air-to-Air Preheater
Cooler
Water
Kiln Fuel
Dosing
Low NOx
Precalciner
Burner
Primary
Air Fan Mill
Cyclone
Conditioning
Preheater
Tower
Burning Zone Kiln Drive
Reciprocating
Grate Cooler
Clinker
Storage
Figure 2: Clinker cooler integrated in the kiln system
More process and equipment related definitions, key parameter and explanations
will be given in the following chapters.
3. CLINKER CONDITIONS AT THE DISCHARGE OF THE ROTARY KILN
The heat recuperation (cooling) process in the clinker cooler has to deal with tough
requirements created by the conditions of the clinker being discharged from the
rotary kiln.
Operation conditions:
• Continuous operation (24/7) over 330 days per year requires reliable
equipment. An unplanned kiln stop results in clinker production losses and
additional operation costs and thus has to be avoided.
• Wide range of clinker production rate (1’000 to 13’000 tonsclinker per day). The
sizing of the equipment has to be done accordingly.
Consistency of the clinker discharged from the kiln:

• Clinker discharge temperature from a modern precalciner kiln is 1400 to
1500 °C. Common stainless steel has a heat resistant of up to approximately
1000 °C. Therefore, cooling and/or heat protection of the equipment is
required especially at the inlet of the clinker cooler.
• Remaining liquid phase down to 1250 °C clinker temperature. The clinker
tends to agglomerate (stick together), in extreme cases “snowman” (built-
ups) on the cooler inlet occur. Rapid cooling is required on the cooler inlet.
• Clinker discharge from kiln to cooler is NOT uniform (coating formation and
coating collapse in the kiln). Kiln gets upset (unstable) from time to time, e.g.
including kiln feed flush during start-up operation.
• Wide range of particle size (from dust to more than 1 m3 size). The clinker
size distribution is NOT uniform.
• Separation of clinker particle sizes due to kiln rotation. In the direction of kiln
rotation the coarse clinker is discharged first while the fine fraction is still
lifted up by the kiln.
Figure 3: Snowman formation on the cooler Figure 4: Clinker separation due to kiln
inlet rotation
Consequence:
It is impossible to predict the clinker condition and clinker fluctuation from
raw materials and fuels exactly.
Typical equipment requirements for clinker coolers are:

• Heat resistant
• Abrasion resistant
• Solid
• Overload resistant
• Heat expansion compensating
• Failure resistant
• Self-protecting
4. OVERVIEW OF CLINKER COOLER TYPES (WORKING PRINCIPLES)
According to the heat transfer principle the clinker cooler types predominantly used
in the cement industry can be sorted in 2 groups:
1. “Counter flow” heat exchange in a suspension of solids (clinker) and gas (air)
2. “Cross flow” heat exchange in a layer (clinker bed)
Figure 5: Heat exchange principles of clinker coolers
The technology of rotary and grate coolers is explained in the following chapters.
Shaft coolers are working with the 3rd principle of heat exchange of “counter flow” in
a layer. This cooler type is not used is cement industry and will therefore not be
explained in detail in this paper.
Figure 6: Heat exchange principle of a shaft cooler
4.1 Counter flow coolers (Rotary coolers)
Two types of rotary coolers are in operation, tube coolers and satellite (planetary)
coolers (see figure 7).
Tube cooler Satellite (Planetary) cooler

Layout: Layout:
Process: Process:
Figure 7: Rotary coolers: Layout and process flows
Working principle of rotary coolers:

The hot clinker from the rotary kiln is discharged into one big tube (“Tube cooler”) or
into several smaller tubes (“Satellite cooler”).
The “Tube cooler” has a separate cooler drive. This enables a separate control of
sintering (burning) time in the kiln and cooling time in the cooler, but it requires the
installation of a kiln hood in the transition zone between kiln and cooler.
The “Satellite cooler” is directly connected to the kiln and does not require a
separate drive.
Separate cooler fans are NOT installed on both cooler types. Therefore the amount
of cooling air is limited to the required combustion air of the kiln (recuperation air).
Lifters are installed in the tubes of both cooler types. They have the duty to improve
the heat transfer between clinker and air. Nevertheless, a lot of air is just flowing
around the clinker particles without contact. Thus, partly colder air is entering the
kiln and reducing the cooler heat recuperation.
Pro and Cons of rotary coolers:
• Simple design (layout)

• No separate cooler fans required
• No cooler exhaust air; No exhaust air dedusting required
• No cooler drive required for satellite coolers
• Limited cooler efficiency (heat recuperation)

• Elevated heat losses (clinker exit temperature and radiation)
• Elevated thermal load of downstream equipment like clinker transport, clinker
storage and cement grinding
• Limited control of heat recuperation and clinker cooling
• Limited clinker production rate (max. 4’000 t/d)
• Limited equipment reliability and availability
• Satellite cooler: NOT suitable for PC (precalciner) technology. The installation of
a tertiary air take-off is impossible
Summary:
Rotary coolers have been installed until the end 70s.
Due to two main reasons these coolers are outdated.
1. After the introduction of the precalciner technology clinker production rates
became higher and rotary coolers reached their limits. Furthermore, the
installation of a precalciner is NOT possible with a satellite cooler.
2. Elevated requirements for heat recuperation and reliability of the clinker
cooler (reduced operation costs). Especially satellite coolers are fairly
maintenance intensive.
Nowadays, new kiln lines are equipped with grate coolers and many existing rotary
coolers are already replaced by grate coolers. Therefore, more details of the rotary
cooler technology are NOT described in this paper.
4.2 Cross flow coolers (Grate coolers)
Clinker discharge from the rotary kiln is done onto a horizontal floor, so called grate,
aeration floor or aeration bottom. The clinker forms a solid layer with a certain height
on this floor and is transported continuously by moving elements.
The floor (grate) is perforated. Cooling air is blown into compartments underneath
the floor, penetrates the clinker through the opening in the floor and passes the
clinker layer vertically (cross flow heat exchange between the hot clinker and the
cooling air).
According to the design of the floor and of the transport elements the following two
cross flow clinker cooler types have been developed:
1. Travelling grate coolers (grate movement in one direction)
2. Reciprocating grate coolers (back and forth movement of the transport
elements)
4.2.1 Travelling grate coolers
The entire grate is moving continuously in one direction to convey the clinker.
Figure 8: Working principle of travelling grate coolers
Two applications are known in the cement industry.
Recupol cooler Revolving Disc cooler

(Polysius; licensed to Allis Chalmers) RDC(concept of CemProTec)
Layout: Layout:
Principle: Principle:
Belt conveyor Rotating disc
Figure 9: Travelling grate coolers
The last unit of the “RECUPOL cooler” has been built in the 1980s.
Due to limited heat transfer and availability (maintenance intensive) this cooler is
outdated and only a few installations are remaining.
The concept of the “Revolving Disc cooler” (RDC) has been introduced a few
years ago. Until now (2012), no RDC has been built yet.
Pro and Cons of travelling grate coolers:
• Simple design of RDC
• Uneven clinker distribution from the kiln cannot be corrected on the belt or disc
• Open (un-compressed) clinker bed may lead to uneven air distribution
(fountains)
• RECUPOL: This cooler requires a lot of maintenance
• RDC: The perpendicular arrangement of the cooler inlet relative to the kiln axis
might influence the flame shape of the kiln burner.
Summary:
The RECUPOL cooler is outdated technology and requires a lot of maintenance,
has limited performance (heat recuperation) and is very large.
The RDC is not built yet (2012) and there is no operating experience. Whether the
desired cooler performance will be achieved is questionable.
Today, travelling grate coolers have very little significance. Therefore no further
details will be described in this document.
4.2.2 Reciprocating grate coolers
The clinker transport elements are moving back and forth continuously to convey the
clinker. The applications mentioned in this chapter are the most common clinker
coolers used in cement industry nowadays.
Three main principles have been developed for clinker cooling:

1. Alternating fixed and movable grates (partly moving aeration floor)
2. Fixed grate with separate transport elements above (fixed aeration floor)
3. Movable grates (movable aeration floor)
4.2.2.1 Alternating fixed and movable grates
The cooling grate is made of L-shape grate plates. Every 2nd row of this grate is
connected to the grate drive and is moving back and forth while the plates in-
between are fixed. On the coolers of IKN and CemProTec every 3rd rows is movable
which requires a slight inclination of the cooling grate.
The clinker is pushed forward with the movable rows, while in the backstroke the
clinker is held back by the vertical part of fixed grate plate and the clinker layer on
top of the fixed plate.
Figure 10: Working principle of alternating fixed and movable grate plates
Figure 11: Alternating fixed and movable grate plates
A typical application of this cooler type is shown in figure 12.
Figure 12: IKN Pendulum Cooler
Pro and Cons of coolers with alternating fixed and movable grate plates:
• Known technology, many reference installations and long term experience

available
• Easy cleaning of the grate (flat surface) for maintenance work, e.g. with shovel
and broom
• High number of gaps on the grate (aeration floor)

• Grate is not tight for clinker, thus clinker fall through (spillage into the air
chamber)
• Hoppers and spillage transport required
• Clinker friction directly on the grate plates (transport elements); no self-
protection layer on the grate plates
• Limited stroke length; high grate speed (15 – 20 min-1), thus high frequency of
grate movement and high wear rate)
• Maintenance intensive; the grate plates are the main wear parts
Remark:
Design of side seal (grate plates at the border sides and side plates) is
essential for lifetime, maintenance cost and clinker fall through.
Summary:
Over many decades the reciprocating grate cooler with alternating fixed and
movable rows has been the dominant solution. This technology reached the limit in
the mid-90s because a further gap reduction was impossible. Thus, developments of
new clinker conveying principles have been started first with the FLS Crossbar
cooler followed by other cooler suppliers.
4.2.2.2 Fixed grate (aeration floor) with separate transport elements above
The clinker falls onto the static cooler inlet section. There, the clinker is prepared for
the heat recuperation process which may require rapid cooling to avoid the
formation of agglomerates.
Afterwards the clinker is conveyed (pushed) by transport elements (cross beams or
longitudinal beams) located above a fixed aeration floor. The transport elements are
working according to the “walking floor principle”, all elements are moving together
forward and they are re-tracked in 2 or 3 groups (see figure 14).
Figure 13: Working principle: fixed aeration floor with separate transport elements above
Figure 14: Walking floor moving principle1
The FLS Crossbar Cooler and Polysius Polytrack Cooler are typical application of
this working principle. The clinker is conveyed by crossbars (FLS) or by longitudinal
tracks (Polysius).
4.2.2.2.1 FLS Crossbar Cooler
Figure 15: FLS Crossbar Cooler; fastening and sealing of the crossbars
Figure 16: FLS Crossbar Cooler: ABC inlet (Air Blaster Controlled)
1
Used in FLS Crossbar Cooler, Polysius Polytrack Cooler, Claudius Peters ETA Cooler, KHD
Pyrofloor Cooler and Fons Delta Cooler
Figure 17: Mechanical flow regulator (MFR)
Main features of the FLS Crossbar cooler:

• Width of the crossbar line ~ 500 mm
• ABC inlet (Air Blaster Controlled)
• Support of the lines by sliding support
• Big compartments with mechanical flow regulators (MFR)
• Contact sealing for the moving elements
4.2.2.2.2 Polysius Polytrack Cooler
Figure 18: Polysius Polytrack Cooler and Inclined Static Grate
Figure 19: Polysius Polytrack Cooler: Track support and ADS
Main features of the Polysius Polytrack Cooler:

• Width of the tracks ~ 350 mm
• Inclined Static Grate without step between the static inlet and aeration floor
• Support of the lines by sliding support
• Compartments with flow regulators (ADS = Air Distribution Switch)
• Contact sealing for the moving elements
4.2.2.2.3 Pro and Cons of coolers with a fixed grate (aeration bottom) and separate transport
elements above
• No grate plates (less wear parts)

• Reduced gaps due to aeration floor technology (sealing is essential!)
• No spillage (clinker fall through); no hoppers and spillage transport required;
reduced installation height required
• Self-protection of the aeration floor (cold material layer insert in the pockets of
the aeration floor)
• Reduced grate speed due to increased stroke length
• Reduced maintenance
• Transport elements (pushers) are moving in the clinker (exposed to wear)

• Transport elements are exposed to the clinker heat (risk of thermal deformation
and burning)
• Cleaning of the grate (aeration floor) for maintenance work requires a vacuum
cleaner. The space in the pockets of the aeration floor and around the transport
elements is not easy to clean.
Remark:
Design of longitudinal seal for the transport elements is essential for lifetime,
maintenance cost and clinker fall through.
Summary:
The FLS Crossbar Cooler in the mid-90s was a milestone in clinker cooler
development and opened the door for several new ideas in the last decade.
The reliability of the coolers with transport elements separated from the grate
depends mainly on the design of the sealing and the thermal load of these transport
elements. Thus, for process interlocking (equipment protection), temperature
sensors are installed at the first elements after the static inlet.
4.2.2.3 Movable grates (aeration floors)
The clinker falls onto the static cooler inlet section. There, the clinker is prepared for
the heat recuperation process which may require rapid cooling to avoid the
formation of agglomerates.
Afterwards the clinker is conveyed by parallel moving floors, each 400 to 600 mm
wide. According to the “walking floor principle”, all floors are moving together
forward and they are re-tracked in 3 groups (see figure 14). On the forward
movement the clinker is laying on the lanes and the friction of the cooler side wall is
the only resistances (==> almost 100% transport efficiency in the forward stroke). In
the backward stroke the clinker is held back by the clinker friction of the standing
neighbor lanes.
Figure 20: Working principle of movable grates (walking floor)
Typical applications of the movable aeration floor technology are the:

• Claudius Peters ETA Cooler,
• KHD Pyrofloor Cooler and
• Fons Delta Cooler
Similar applications of the walking floor coolers are available, e.g. in China
4.2.2.3.1 Claudius Peters ETA Cooler,
Figure 21: Claudius Peters ETA Cooler
Figure 22: Claudius Peters ETA Cooler: Aeration scheme
Figure 23: Claudius Peters ETA Cooler: Static inlet and support roller
Main features of the Claudius Peters ETA Cooler:
• Lane width 600 mm
• HE-Module (static inlet) with multichannel aeration
• Support of the lanes by rollers
• Separate side aeration in recuperation zone
• Small compartments without flow regulators
• Lane sealing with integrated pneumatic dust transport
4.2.2.3.2 KHD Pyrofloor Cooler
Figure 24: KHD Pyrofloor Cooler
Figure 25: KHD Pyrofloor Cooler: Flow regulator
Main features of the KHD Pyrofloor Cooler:

• Support of the lanes by rollers
• Big compartments with flow regulator for each cassette
• Contact sealing between the lanes
4.2.2.3.3 Fons Delta Cooler
Figure 26: Fons Delta Cooler with “Four Joint Mechanism” and “STAFF” flow regulator
Main features:
• Support of the lanes by “Four Joint Mechanisms”
• Big compartments with “STAFF” flow regulator for each grate plate
• Contact sealing between the lanes
4.2.2.3.4 Pro and Cons of coolers with movable grates (aeration bottoms)
• No grate plates (less wear parts)

• Reduced gaps due to aeration floor technology (sealing is essential)
• No spillage (clinker fall through); no hoppers and spillage transport required;
reduced installation height required
• Self-protection of the aeration floor (cold material layer insert in the pockets of
the aeration floor)
• Reduced grate speed due to increased stroke length
• No transport elements (pushers) working inside the clinker layer
• Minimized maintenance
• Cleaning of the grate (aeration floor) for maintenance work requires a vacuum
cleaner. The space in the pockets of the aeration floor is not easy to clean.
Remark:
Design of longitudinal seal between the lanes is essential for lifetime,
maintenance cost and clinker fall through.
Summary:
The concept of parallel moving aeration floors has the potential to be the most self-
protecting cooler type. All moving parts are mainly covered by the material
remaining in the pockets of the lanes. There are NO elements moving inside the
clinker layer.
The reliability of coolers with movable floors (lanes) depends mainly on the design
and material of the sealing between the lanes, wear protection of the lanes, e.g.
hardfacing, the thickness of the protection layer, the availability of the lane support
elements and the capability of heat deformation compensation. In this regards there
are difference between the 3 solutions described above.
4.2.3 Special cooler applications
The following special cooler application will not be described in this paper:
• Recirculation air cooler (Duotherm process)
• Dualpass (development by Polysius, not used anymore)
• Cross Motion Grate (Claudius Peters; only one installation)
• Single movable floor with fixed beams above (Claudius Peters; only one
installation for expanded clay (Leca))
• g-cooler (Claudius Peters; indirect after-cooling)
• Fluidized bed cooler (development in Japan)
Further information is available at HGRS-CMS-TPT.
5. ENERGY FLOWS AND COOLER HEAT BALANCE
Energy flows can be illustrated in Sankey diagrams. All energy flows entering and
leaving the clinker cooler are shown. An example of a grate cooler is given in
figure 27.
Figure 27: Energy flows of a grate cooler
In addition the air flows can be shown in a flow sheet.

The most common method to evaluate the thermal performance is a heat balance.
Figure 28: Grate cooler flow sheet

Figure 29: Cooler heat balance
The principle of all this methods is

“Heat Input = Heat Output” (energy balance).
Specific air flows and energy flows:

As for other components of the kiln system, specific figures for clinker coolers refer
to 1 kg of clinker. This eliminates the influence of plant size and allows direct
comparison of clinker coolers of different types and sizes.
The “specific cooling air volume [Nm3/kgcli]” indicates how much air is needed to
cool down the clinker from cooler inlet to cooler outlet. In the heat balance (figure
21) 1.96 Nm3/kgcli is required to realize the clinker temperature drop from 1450 °C to
166 °C.
Heat inputs:
Heat inputs are the hot clinker entering the cooler and the cooling air and false air
entering the cooler. If the cooling air temperature and reference temperature of the
heat balance are same, the heat input from cooling air is “Zero”.
Heat outputs:
The heat outputs are the sum of recuperated heat and cooler heat losses.
Recuperated heat:
Heat content of the secondary and tertiary air going back to the kiln system
Heat losses:
Heat content of cooler exhaust air, of the clinker leaving the cooler and radiation
loss of the cooler.
5.1 Actual cooler efficiency (heat recuperation)
The formula to evaluate the actual cooler efficiency is shown below.

It is either the recuperated heat divided by the heat input from clinker or 1 minus the
sum of cooler heat losses (exhaust, clinker exit and radiation) divided by the heat
input from clinker.
Figure 30: Definition of the actual cooler efficiency
Remark:
Since the recuperated heat is proportional to hot air used for combustion, an
efficiency figure is only meaningful if it is related to a heat consumption figure
(respectively a recuperation air flow).
Figure 31 shows the energy balance at different cooler efficiencies.
Figure 31: Influence of cooler efficiency on the cooler heat losses
5.2 Normalized cooler efficiency:

For the purpose of direct comparison of different combustion (recuperation) air
requirements, cooler types and sizes, the normalized cooler efficiency has been
introduced. The actual cooler efficiency at a certain specific recuperation air is
converted to the normalized cooler efficiency at 0.8 Nm3/kgcli recuperation air2.
2
The formula is available in the “Reference guide for process performance engineers”
6. GRATE COOLERS: DESIGN AND OPERATION
6.1 Main functions and components
Main functions and components of a grate cooler are listed in table 1.
Function Components
Clinker aeration Aeration system (air distribution
system) consisting of fans, air ducts,
compartments and the openings in the
aeration floor (e.g. grate plates)
Clinker conveying Grate drive and movable elements of
the aeration floor including transport
elements above, if applicable
Clinker crushing Roller crusher or
Hammer crusher
Table 1: Main functions of a clinker cooler
An effective (efficient) heat transfer from clinker to air depends on the design and
operation of the aeration system and the grate drive.
In the case of stage coolers with intermediate crushing (figure 32) also the clinker
crusher plays an active role for the heat transfer. With intermediate crushing the
crushed clinker is cooled on the last grate. This results in lower and more stable
average clinker exit temperature Furthermore the available heat in the cooler
exhaust air is increased.
Figure 32: Step cooler: Example Polysius Polytrack
Remark:
Depending on the cooler application other side functions, like clinker spillage
collection, discharge and transport, might be required. They are not part of this
paper.
6.2 Cooling (heat recuperation) zones of grate coolers
Modern grate coolers can be divided in three zones with different requirements
regarding aeration and conveying of the clinker:
• 1st zone: Static inlet
• 2nd zone: Remaining recuperation zone
• 3rd zone: Cooling zone
Figure 33: Zones of a grate cooler
Zone 1: Static cooler inlet (1st part of recuperation zone):
The static cooler inlet is the most important zone in the cooler and has to deal with
tough conditions like discharge fluctuations, coating fall, kiln upsets, liquid phase
and clinker segregation.
The main task on the static inlet is to prepare the clinker for the entire heat
recuperation process. If things go wrong on the static, e.g. agglomerate formation,
it is impossible to correct this in the remaining cooler.
Furthermore, equipment protection is important, therefore the grate plates on the
static inlet are all fixed (i.e. not moving) and a cold clinker (material) layer remains
on the static inlet. The thermal load is reduced and grate plates do not burn
anymore when operating the static inlet with sufficient air, especially during start-up.
Remark:
Grate plate protection was the initial reason to introduce static inlets more than two
decades ago.
A downwards slope of the grate plates (usually between 5 and 14°) and sufficient
aeration (up to 2 Am3/m2/s) is required to assure clinker distribution and clinker
conveying on the static inlet and, most important, to avoid that the clinker sticks
together (agglomerates). Although, dust circulation may increase due to over-
aeration, increased air flows are strongly recommended. Sufficient fan pressure is
required.
The static inlet has to be 100% sealed to avoid air losses, e.g. via openings in
compartment walls, in this essential area.
Zone 2: Remaining recuperation zone:
In this area the grate speed and air distribution have to be adjusted to achieve high
and stable recuperation air temperatures. To improve the heat transfer the required
over-aeration on the static inlet can be compensated by reduced aeration in the
remaining recuperation.
The most important parameter is the clinker bed height. Sufficient fan
pressure is required to enable cooler operation with 600+ mm or even better
with 800+ mm.
Zone 3: Cooling zone:
The objective in the cooling zone is a low clinker end temperature to minimize the
thermal load of the downstream equipment like clinker transport, clinker storage and
cement grinding. Cement quality is also negatively influenced by elevated clinker
exit temperatures.
In some cases a high energy potential of the cooler exhaust is aimed for additional
waste heat recovery.
6.3 The aeration system
Figure 34 shows the basic layout of the grate cooler aeration system.
• Cooling air fans are arranged around the clinker cooler.
• Air ducts are connecting the fan outlets (fan pressure side) with the
undergrate compartments.
• A positive pressure is developed in the undergrate compartments.
• The air penetrates through the openings in the grate (aeration floor) into the
clinker and passes through the clinker layer on top of the grate.
• The slightly negative pressure in the cooler upper section on top of the
clinker layer is created by the kiln ID-fan on one side and the cooler exhaust
air fan on the other side.
• Thus, the cooler aeration system starts from the inlet of the fans (suction
side) and ends at the surface of the clinker bed.
Figure 34: Basic layout of the aeration system
6.3.1 Configurations of the aeration system
Chamber aeration is the basic configuration for grate coolers. Especially in the 90s
several other configurations have been developed. An overview of these
configurations is given in the following table.
No. Aeration system Scheme Description

a) Chamber • The air duct ends at the cooler side wall.
aeration • The cooling air enters the compartment and
leaves via the openings in the grate into the
clinker bed.
• Special air distribution devices do not exist.
Simple design
No additional pressure drop required
b) Chamber • The air duct ends at the cooler side wall.
aeration with flow • For additional air distribution flow regulators,
regulators, flow flow limiters or orifices are installed
limiters or underneath the openings in the grate.
orifices Adjustment during operation not possible
Additional pressure drop required
c) Direct aeration • Air ducts are installed between the fan outlet
and the grate plates. The air is guided
directly to the plates (small aeration fields).
Additional pressure drop required for the air
distribution ducts
Additional sealing air required
d) Mixed aeration • Direct aeration in hot clinker areas only, e.g.
(Fishbone at the border sides to cool down red rivers.
aeration, Direct • The remaining area of the compartment is
Side Aeration) chamber aerated.
No sealing air required
Additional pressure drop required for the air
distribution ducts in the hot clinker areas
e) Multi-channel • The aeration field is divided in smaller fields
aeration for the by air channels.
static inlet and/or • The adjustment of air flow for each small
hot clinker areas field is done by flaps.
• Due to reduced air velocity in these
channels the required pressure drop is
moderate.
Simple design (good compromise between
chamber and direct aeration in special
areas)
Table 2: Configurations of the grate cooler aeration system
Today, most of the cooler suppliers are using chamber aeration, flow regulators of
multi-channel aeration. Because of the more complicated equipment with many
elements, the higher electrical energy consumption and partly high maintenance
requirements, direct aeration is NOT used anymore for new cooler installations.
6.3.2 Aeration scheme
The aeration scheme is one of the key documents of the grate cooler.
It indicates the size of the compartments (aerated surface), the type of aeration and
in some cases the fan data. These data are required for an air distribution and
clinker cooling curve check.
Figure 35: Example of grate cooler aeration scheme
Features of this aeration system (figure 35):

• Static inlet:
o Direct aeration with fan VE1; aerated surface (active grate area): 3.2 m2.
• 1 grate:
st
o Direct aeration of chamber 1 (fan VE2); including sealing air fan VE9
o DSA (Direct Side Aeration) of chamber 2 with fan VE3 (chamber
aeration) and fan VE5 for DSA
o Chamber aeration of chamber 3 (fan VE4)
• 2nd grate:
o Chamber aeration of all 3 compartments with fans VE6, VE7 and VE8
6.3.3 Required fan pressure
To enable the comparison of different aeration concepts the required fan pressure
should be split into 3 parts.
Part 3
Part 2
Part 1
Figure 36: Pressure drop of the aeration system
Part 1:
The total pressure increase of the fan from inlet to outlet includes the pressure drop
of the:
• inlet nozzle for flow measurement,
• silencer,
• inlet damper, if applicable and
• impeller
These are internal pressure losses of the cooling air fan.
They are NOT available for clinker cooling.
Part 2:
Pressure drop of the cooler equipment, including:
• air ducts,
• air channels of direct aeration system, if applicable,
• Flow regulators, if applicable and the
• Aeration floor (grate plates)
This is the pressure drop of the grate system (see figure 36).
Part 3:
Pressure drop of the clinker bed depending on:
• Clinker temperature,
• Clinker bed height,
• Clinker granulometry and
• Void volume (empty space between clinker granules, density)
The available pressure at the fan outlet is important for heat recuperation in
grate coolers. Insufficient fan pressures are limiting the operation with a high
clinker bed.
6.3.4 Air distribution check and clinker cooling curve calculation
The air distribution check and clinker cooling curve calculation is a kind of quality
check for the actual aeration system.
With this program the flow and pressure profile as well as the compartment sizes
are checked.
To proceed with this evaluation the actual aeration scheme of the cooler is required.
Figure 37: Aeration scheme
6.3.4.1 Flow and pressure profile
The zones of the clinker cooler require a certain specific air flow (Am3/m2/s). Initially
these values are required for the fan design and later these design data are
compared with the actual operation data to detect possible bottlenecks.
For sufficient clinker preparation the fans on the static inlet have to provide a
minimum specific air flow of 1.8 Nm3/m2/s and a minimum pressure at the fan outlet
of 120 mbar3.
Figure 38: Flow / Pressure profile design Figure 39: Flow / Pressure profile in operation
A comparison of the flow and pressure profiles with the design data (figure 38) and
operation data (figure 39) is shown above.
Operation and design are matching fairly well in this example (see red circle). The
air flows and pressures of compartment 1 to 5 decrease constantly from the front to
the back end of the cooler. Air distribution and pressure development along the
cooler correspond with the clinker cooling curve. Hot clinker requires more cooling
air and pressure than the cold clinker.
In the next example design and operation do NOT match.

Although the air flow decreases from compartment 1 to 4 the pressure stays the
same (red circle in figure 41). This indicates air losses between these
compartments. The air escapes towards the end of the cooler.
Openings in the compartment walls or other leaks have to be closed to improve air
distribution and heat recuperation.
3
According to Holcim Standard Design Criteria, Version April 2012
Figure 40: Flow / Pressure profile design Figure 41: Flow / Pressure profile in operation
6.3.4.2 Clinker cooling curve calculation
The clinker is hot at the cooler inlet (~ 1400 °C) and should be cooled down to a
temperature of 100 to 150 °C with the lowest possible cooling air volume.
Hot clinker has a higher pressure resistance than cold clinker. At the hot end the
cooling air is heated up more while passing the clinker bed. Thus, air velocity and
pressure drop increase.
Therefore, most of the cooling air would escape towards the end of the cooler if
there were no barriers. Thus, the cooler lower section is divided into
compartments, also called air chambers.
Targets are:
• Controlled air distribution (force the air to go into the hot clinker).
• Minimize (eliminate) air losses from compartment to compartment and air
losses via cooler casing, hoppers and hopper discharge gates
Assuming no air losses (i.e. the entire cooling air entering the compartment is also
blown into the clinker on top of this compartment), a clinker cooling curve can be
calculated based on the operation data (figure 39).
If the clinker temperature drop per compartment (aeration unit) is lower than 200 °C
the cooling air distribution within this compartment can be considered as efficient.
With higher values than 200 °C the cooling air has a tendency to enter the clinker at
the end of the compartment (see figure 42).
Figure 42: Air distribution with short and long compartments
Figure 43: Clinker cooling curve calculation
Compartment 1 (area of fan 4) has a clinker temperature drop of 364 °C (figure 43).
This compartment, located in the recuperation zone, is certainly too long for an
efficient heat transfer. Thus, a split into 2 compartments has to be considered.
Notes:
• If flow regulators are installed, longer compartments might be acceptable.
Remark:
Compartment sealing and compartment sizing are essential for efficient heat
recuperation and clinker cooling!!!
6.4 Grate drive
The movement of the grate is realized by the grate drive.

Two types of grate drives are used:
a) Mechanical grate drive
b) Hydraulic grate drive
Figure 44: Mechanical grate drive Figure 45: Hydraulic grate drive
The hydraulic grate drive for clinker coolers has been introduced in the 1980s.
Due to linear force transmission and low space requirement at the cooler site, new
grate coolers are exclusively equipped with hydraulic grate drives.
6.4.1 Check of the clinker bed height
Possible limitations for clinker bed height are:

• Insufficient pressure at the fan outlet due to
o Elevated pressure drop of the damper
o Elevated pressure drop of the silencer
o Poor quality of the fan
o Worn out impeller
o Fan motor or frequency converter too small
• Compartments too long
• Cooler too wide
• High pressure drop of the grate plates and/or air ducts
Calculation (estimation) of clinker bed height:

There are 2 ways to calculate (estimate) the clinker bed height on the movable grate
section.
1st way:
Rule of thumb:
100 mm clinker bed = 10 mbar (for the fan behind the static inlet)
2nd way:
Both ways are integrated in an Excel program for the cooler data check, a tool that
is available on the Holcim Portal.
6.5 Clinker crusher
The following comparison of roller and hammer crusher indicates clear process and
maintenance advantages of the roller crusher. Thus, the roller crusher is a must for
all new cooler installations.
Figure 46: Comparison of roller crusher and hammer crusher
By experience the lifetime of crushing tools can be estimated as shown in table 3.
No. Crushing tool Estimated Comment

lifetime
HC 1 Casted hammer (brittle material) ~ 0.5 years
Except damage by impact if
HC 2 Bi-metallic hammer (wear < 1 year
hammer crusher is stopped
resistant (brittle) top with ductile
immediately by a big boulder
fastening area)
RC 1 Casted crushing ring (brittle > 3 years Except thermal shock impact,
material) e.g. by kiln feed flush
RC 2 Casted crushing ring of ductile > 10 years A roller crusher with this
material with hardfaced edges of crushing rings almost no
the teeth maintenance is required
Table 3: Crushing tool lifetime comparison
Mainly due to the speed of the crusher there are huge differences between
hammers and crushing rings. The material or material combination has also a
significant influence on service lifetime.
Due to the short lifetime of the hammers, a completely equipped spare rotor should
be available in the workshop. By this measure, unplanned downtime with the
hammer crusher can be minimized.
Figure 47: Crushing ring Figure 48: Hammer
7. GRATE COOLER CONTROL
The grate cooler control is realized by 3 control loops:

1. Grate speed (clinker bed height) control by reference undergrate pressure
(or in some cases by reference level) and oil flow control of the hydraulic
pumps of the grate drive.
2. Air flow control of each fan by flow measurement at the fan inlet and VSD
(variable speed drive) control of the cooler fans.
3. Kiln hood pressure control by speed control of the cooler exhaust air fan.
Figure 49: Control loops of the grate cooler
The clinker cooler control strategy is an indirect control of the main cooler process
temperatures (Tsecondary air, Ttertiary air and Tclinker).
7.1 Alarms and process interlocks
To prevent equipment damage and to minimize failures and downtime alarms and
process interlocks are implemented.
Typical examples for alarms and interlocks for grate coolers are:
• Temperature of the grate plate: Overheat protection of the transport element
• Compartment temperature: Avoid deformation of the cooler structure by
excessive clinker fall through
• Exhaust air temperature: Protection of the filter equipment
• Clinker crusher and clinker transport operation: Avoid overfilling of the cooler
• Grate movement (kiln feed release): Avoid overfilling of the cooler
Interlocks are just active in automatic operation!

Active interlocks protect the equipment and enable a quick re-start after
failures. With active interlocks the un-planned downtime is minimized.
8. TYPICAL PROBLEMS OF CLINKER COOLER
Figure 50: Typical clinker cooler problems
Most of the cooler problems are related to air losses (leaks)!

These are:
• Burnt plates
• Poor compartment (UG) seal
• Snowman (also partly related to the design of the static inlet and clinker
condition from the kiln)
• Dust leakage and air leakage via hoppers discharge gates
• Geyser (fountains)
• Red river (also partly related to grate inclination)
• Fritting / caking
Other problems are related to the condition of the equipment:

• Thin clinker bed (insufficient fan pressure; weak cooler structure and/or grate
drive)
• High clinker fall through (poor gap management on the grate plates)
The right design, operation and maintenance of the clinker cooler help to
minimize or even avoid problems!
Team work between maintenance, production and process is required to

overcome cooler problems and to optimize the mechanical and thermal
performance of the clinker cooler!
!!!
9. COOLER LOADS AND SIZING RULES
By operating experience the following sizing rules for grate coolers have been
developed. The actual values are listed in the actual version of the Holcim Standard
Design Criteria. The examples are from the version April 2012.
Specific grate area load:

To assure sufficient active cooling surface the target value is 40 t/d/m2
Specific grate width load:

To enable cooler operation with a sufficient clinker bed height and with an
acceptable grate speed the target value of the specific grate width load shall be
within the range of
+/- 150 t/d/m of 1080 t/d/m + Clinker production [t/d] x 0.08 m-1
Figure 51: Specific grate width load
Specific cooling air installed:

To assure sufficient clinker cooling (clinker exit temperature) a minimum specific
cooling air volume of 2.0 Nm3/kgcli has to be installed on the fans.
Air velocities in cooler upper section:
Low air velocities in the cooler upper section are important to minimize the dust
circulation in secondary, tertiary and exhaust air.
For new kilns the Holcim targets for the air velocities in the cooler upper section are:
• Cooler throat: 5 m/s
• Tertiary air take-off: 5 m/s
• Tunnel velocities: 8 m/s
• Exhaust air take-off: 7 m/s
The actual velocities at the tertiary air take-off, tunnel and exhaust air take-off are on
the high side (see example figure 52). But a reduction of these velocities would
require modifications, which seem to be only feasible if the cooler would be replaced
(high costs). Thus, higher velocities have to be accepted for existing kilns in some
cases.
Figure 52: Example: Air velocities in the cooler upper section
10. TYPICAL OPERATION TARGETS FOR GRATE COOLERS
The “typical operation targets for modern clinker coolers” are shown in table 4.
Table 4: Typical operation targets for grate coolers
Based on these targets possible improvements and bottlenecks can be evaluate for
each particular cooler installation.
Examples of best practice are:

• The specific electrical power consumption [kWh/tcli] is the same with a
high clinker bed and less cooling air and with a medium clinker bed
and a higher cooling air requirement!
• The specific kiln heat consumption [kJ/kgcli] is lower with high clinker
bed (see “Four Tens Rule”).
• Small and long coolers are more efficient than wide and short coolers.
• Pressure and flow reserves on the static inlet are required to be flexible
in cooler operation.
Figure 53: The “Four Tens Rule”
11. THE “THREE GOLDEN RULES OF CLINKER COOLING”
Figure 54: The “Three Golden Rules of Clinker Cooling”
Following these rules is mandatory for excellent clinker cooler performance!

!!! follow the “Three Golden Rules of Clinker Cooling” and to optimize the
mechanical and thermal performance of the clinker cooler!
!!!
12. KEY MESSAGES FOR CLINKER COOLERS
1. The clinker cooler is a vital part of the kiln system and has a decisive influence
on the performance of the plant. Three indicators characterize a good clinker
cooler:
• Maximum heat recuperation
• Effective clinker cooling with minimum cooling air flow
• Unrestricted availability
2. The heat recuperation (cooling) process in the clinker cooler has to deal with
tough requirements created by the conditions of the clinker being discharged
from the rotary kiln.
3. The thermal performance (cooler efficiency) is evaluated by an energy balance:
Principle: “Heat Input = Heat Output”
4. The heat transfer principle predominantly used in clinker coolers is “Cross
flow” heat exchange in a layer (clinker bed).
5. The three principles of reciprocating grate cooler are:
a) Alternating fixed and movable grates (partly moving aeration floor)
b) Fixed grate with separate transport elements above (fixed aeration floor)
c) Movable grates (movable aeration floor)
6. Aeration system, grate drive and clinker crusher are the main components of a
clinker cooler. Preferred solutions are chamber aeration without flow regulator,
hydraulic grate drive and roller crusher.
7. Modern grate coolers can be divided in three zones with different requirements
regarding aeration and conveying of the clinker:
o 1st zone: Static inlet
o 2nd zone: Remaining recuperation zone
o 3rd zone: Cooling zone
The static inlet is the most import area of the clinker cooler!
8. The aeration scheme is one of the key documents of the grate cooler.
9. The available pressure at the fan outlet is important for heat recuperation
in grate coolers. Insufficient fan pressures are limiting the operation with a
high clinker bed.
!!!
10. Most of the cooler problems are related to air losses (leaks)!
11. The air distribution check and clinker cooling curve calculation is a quality check
of the actual aeration system.
12. Compartment sealing and compartment sizing are essential for efficient
heat recuperation and clinker cooling!!!
!!!
13. To enable cooler operation with a sufficient clinker bed height and with an
acceptable grate speed the value of the specific grate width load is important.
14. Low air velocities in the cooler upper section are important to minimize the dust
circulation in secondary, tertiary and exhaust air.
15. Active interlocks protect the equipment and enable a quick re-start after
failures. With active interlocks the un-planned downtime is minimized.
16. By experience, the specific electrical power consumption [kWh/tcli] is the same
with a high clinker bed and less cooling air than with a medium clinker bed and a
higher cooling air requirement!
17. The specific kiln heat consumption [kJ/kgcli] is lower with high clinker bed
(see “Four Tens Rule”).
18. Small and long cooler are more efficient than wide and short coolers.
19. Pressure and flow reserves on the static inlet are essential to be flexible in
cooler operation.
20. Follow the “Three Golden Rules of Clinker Cooling”:
1) Keep the clinker on the grate !!!
2) Keep the cooler tight
3) Keep the grate speed low
21. Compare your actual cooler performance with the “typical operation
targets for modern clinker coolers”
22. Operate with the highest possible clinker bed depth! Target 600 - 1000 mm!

!!! overcome cooler problems and to optimize the mechanical and thermal
performance of the clinker cooler!
!!!

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Clinker Coolers

• Maximum heat recuperation

This paper gives an overview about process technology, requirements, types,

2. MAIN TASKS OF THE CLINKER COOLER

The clinker cooler has two main tasks:

Figure 1: Overview of the clinker cooling process

Burning Zone Kiln Drive

Figure 2: Clinker cooler integrated in the kiln system

Consistency of the clinker discharged from the kiln:

Typical equipment requirements for clinker coolers are:

4. OVERVIEW OF CLINKER COOLER TYPES (WORKING PRINCIPLES)

Figure 5: Heat exchange principles of clinker coolers

Figure 6: Heat exchange principle of a shaft cooler

Tube cooler Satellite (Planetary) cooler

Figure 7: Rotary coolers: Layout and process flows

Working principle of rotary coolers:

Pro and Cons of rotary coolers:

• Simple design (layout)

• Limited cooler efficiency (heat recuperation)

4.2 Cross flow coolers (Grate coolers)

4.2.1 Travelling grate coolers

Figure 8: Working principle of travelling grate coolers

Two applications are known in the cement industry.

Recupol cooler Revolving Disc cooler

Pro and Cons of travelling grate coolers:

• Simple design of RDC

Three main principles have been developed for clinker cooling:

4.2.2.1 Alternating fixed and movable grates

Figure 11: Alternating fixed and movable grate plates

Figure 12: IKN Pendulum Cooler

• Known technology, many reference installations and long term experience

• High number of gaps on the grate (aeration floor)

4.2.2.2.1 FLS Crossbar Cooler

Main features of the FLS Crossbar cooler:

Figure 18: Polysius Polytrack Cooler and Inclined Static Grate

Figure 19: Polysius Polytrack Cooler: Track support and ADS

Main features of the Polysius Polytrack Cooler:

• No grate plates (less wear parts)

• Transport elements (pushers) are moving in the clinker (exposed to wear)

4.2.2.3 Movable grates (aeration floors)

Figure 20: Working principle of movable grates (walking floor)

Typical applications of the movable aeration floor technology are the:

Figure 21: Claudius Peters ETA Cooler

Figure 22: Claudius Peters ETA Cooler: Aeration scheme

4.2.2.3.2 KHD Pyrofloor Cooler

Figure 24: KHD Pyrofloor Cooler

Figure 25: KHD Pyrofloor Cooler: Flow regulator

Main features of the KHD Pyrofloor Cooler:

• No grate plates (less wear parts)

4.2.3 Special cooler applications

Figure 27: Energy flows of a grate cooler

In addition the air flows can be shown in a flow sheet.

Figure 28: Grate cooler flow sheet

The principle of all this methods is

Specific air flows and energy flows:

5.1 Actual cooler efficiency (heat recuperation)

The formula to evaluate the actual cooler efficiency is shown below.

Figure 30: Definition of the actual cooler efficiency

Figure 31: Influence of cooler efficiency on the cooler heat losses

5.2 Normalized cooler efficiency:

6.1 Main functions and components

Main functions and components of a grate cooler are listed in table 1.

Figure 32: Step cooler: Example Polysius Polytrack