Course 3 – Clinker Production

3.6 Clinker Coolers

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 78–1
Fax: +49 211 45 78–296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Construction and Operation............................................................................ 1
2.1 Cooling Zones..................................................................................................... 1
2.2 Grate Coolers ...................................................................................................... 2
2.2.1 Aeration System.................................................................................................. 2
2.2.2 Grate Plates......................................................................................................... 4
2.2.3 Roll and HammerCrushers ................................................................................. 6
2.2.4 Types of Grate Cooler......................................................................................... 8
2.2.5 New Generation of Grate Coolers ...................................................................... 9
2.3 Rotary Coolers .................................................................................................... 11
2.4 Satellite Coolers (Planetary Coolers).................................................................. 13
2.5 Other Clinker Coolers......................................................................................... 15
3 Operation and Quality ..................................................................................... 16
i
4 Health and Safety Practices ............................................................................. 18

5 Wear, Maintenance and Inspection ................................................................. 19

6 Environmental Protection ................................................................................ 20

7 Questions on Course LB 3.6 – Clinker Coolers ............................................. 21
Solutions............................................................................................................................... 22
Glossary ............................................................................................................................... 23

Index..................................................................................................................................... 24

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1 Introduction
The clinker cooler is positioned after the kiln outlet as the final unit in the thermal clinker Types
production process. The following types of coolers are used for clinker cooling:
 grate coolers,
 satellite or planetary coolers and
 rotary coolers.
Modern plants with a cyclone preheater, a precalciner , a tertiary air duct and a grate
cooler represent the current state of the art in this field. The tertiary air is drawn either
from the kiln hood or from the grate cooler. Developments in grate cooler technology
have led to a considerable improvement in the thermal efficiency and availability of kiln
plants.
In this course you will learn about the basic concepts of clinker cooling and the different
clinker cooler designs. In particular you will learn more about the most modern design
type: the ’grate cooler’.
Course Summary
1

2 Construction and Operation

The combustion air required for the burning process as secondary air and possibly also
as tertiary air is preheated to the highest possible temperature by rapid cooling of the
sintered hot clinker. In this way, the requisite temperature of the kiln feed, or sintering
temperature, of approx. 1,450 ◦ C is achieved in the sintering zone of the rotary kiln to
form clinker with the lowest possible fuel consumption.
The rate of cooling of the clinker in the various temperature ranges has a major effect
on the properties of the cement produced from the clinker, in particular with respect to
composition, setting and hardening.
The cement clinker is therefore cooled in accordance with a temperature regime based on
quality requirements. The cold clinker should be cooled to low temperatures as quickly
as possible so that it can be transported, stored and ground to make cement.

Requirements of a Clinker Cooler

The following requirements must be satisfied by a clinker cooler, irrespective of its design: Requirements
 quickest precooling possible
 maximum heat recovery from the hot, finish-burnt clinker
 sufficient cooling of the clinker
 high level of availability and long service life
 controllability that is as effective and as simple as possible

2.1 Cooling Zones

The cooling section of a kiln plant can be divided into three zones on the basis of the
material and energy aspects:
 precooling zone 3 Zones
 recuperation zone (heat recovery)
 cooling zone
In the precooling zone the clinker is cooled from the sintering temperature (1,450 ◦ C) to
approx. 1,250 ◦ C by the incoming secondary air while it is still in the kiln. The clinker

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 2 Construction and Operation

then drops into the cooler and passes into the recuperation zone where the combustion
air is heated. The clinker is cooled to its final temperature (approx. 100-120 ◦ C) in the
cooling zone.
In contrast to rotary coolers and satellite coolers, some of the cooling air in grate coolers
generally leaves the cooler as exhaust air. After dedusting, this exhaust air may, for
example, be used in an energy-efficient way to dry fuels. It is also possible to convert
surplus energy into electricity. Fig. 2.1-1 shows the individual zones of the cooling section
and the above-mentioned requirements of the clinker cooler.

Rapid precooling

Simple
controllability

Optimum heating of Maximum

combustion air availability

Optimum
clinker cooling
2
Minimal
plate wear

Precooling Recuperation zone Cooling zone

zone

Figure 2.1-1: Zones of the Cooling Section and Requirements of the Clinker Cooler .

2.2 Grate Coolers

Cooling Principle Despite having very different designs, all grate coolers operate by the same cooling princi-
ple: once discharged from the kiln the clinker lies on a grate and cooling air flows through
it from below. It is possible to generate different air flow rates in the different temperature
zones of the cooler by using several fans underneath the grate.
Increased Air Volume However, this optimized clinker cooling process means that grate coolers have an increased
specific air requirement, so the excess air must be discharged as cooler exhaust air or as
central exhaust air and dedusted. However, due to its temperature of up to 400 ◦ C this
excess air can be used for drying and energy recovery.
Differences between The main characteristics that differentiate grate coolers are the different methods of clinker
Designs transport. Other differences include the type of air feed and air flow and the shape of the
grate plates.
At this point of the online course you would now see an animation explaining the structure
of a grate cooler instead of this picture.
Further details on the grate cooler will be explained in the following units:
 »Aeration System«, p.2
 »Grate Plates«, p.4
 »Roll and HammerCrushers«, p.6
Course Summary
 »Types of Grate Cooler«, p.8
 »New Generation of Grate Coolers«, p.9

2.2.1 Aeration System

Direct Aeration and/or Coolers have been produced with direct aeration, chamber aeration or combinations of
Chamber Aeration

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 2.2 Grate Coolers

the two systems. In the most recent types of cooler the reciprocating grates are chamber
aerated. The static grate at the cooler inlet is aerated directly with a high flow resistance,
which is intended to achieve a more uniform distribution of air and clinker. Air channelling
is largely avoided through the use of grate plates where the cooling air exits horizontally
(Fig. 2.2-1).

Figure 2.2-1: Schematic Diagram of Direct Aeration .

With direct aeration the cooling air is fed directly to the grate plates through ’air beams’.
In conventional designs the aeration is carried out over the entire chamber under the grate.
This enables selective and, if neccessary, sectional aeration of the plates at high pressure
as well as a reduction in the amount of cooling air required owing to the greater imperme-
ability of the system. The high pressure is required in order to overcome the high grate
resistance and the resistance of the clinker bed above it. The air supply system to the first
grate is designed in sectors so that the amount of cooling air and therefore the pressure of
the cooling air can be adjusted to suit the depth of the clinker layer and the particle size
distribution. With high clinker throughputs in particular, the air beams are divided or the
discharge region is configured as a segment with extra aeration. There are differing views
on the extent to which the rest of the recuperation region should also be directly aerated
or conventionally chamber aerated, but chamber aeration tends to be the preferred choice.
The cooling region is always chamber aerated.
The majority of cooler manufacturers divide the entire cooling grate both transversely and Sectors with Separate
longitudinally into a large number of sectors that can be aerated separately (Fig. 2.2-2). Aeration

This means that cooling conditions can be better adapted to the thickness and granulometry
of the particular clinker layer. In some cases the directly aerated part of the grate area has
now been reduced again in order to limit the electrical energy consumption of the fans.
If, in addition to the static preliminary grate, the rest of the cooler is also chamber aerated,
but a high cooling air discharge speed is desired, it is necessary to achieve a high degree
of impermeability between the grate plates and the rows of grates as well as at the side
seals. In this case only every third row of grates is movable. In addition, grate plates with
a very high resistance are used in this region. The clinker layer may also be deeper, and
the amount of cooling air may be reduced, by uniform distribution of the clinker falling
from the kiln onto the first grate.
Tab. 2.2-1 shows the advantages and disadvantages of the two methods of aeration. Advantages and
Disadvantages of Direct
 With direct aeration the cooling air is fed to the plates via pipelines or optionally
Aeration and Chamber
via the grate beams. A greater fan output is required due to the additional loss of Aeration

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 2 Construction and Operation

Figure 2.2-2: Division of Zones in Clinker Coolers (Source: Video KHD) .

pressure. It is also necessary to transfer the air from stationary fans to the moving
rows of plates, so seals are necessary. The flexible hoses used in the past have proved
inadequate for the rough operating conditions in cement works and nowadays sliding
seals are generally used.
 In contrast, with chamber aeration it is not possible to supply the air selectively to the
highly loaded cooling areas. However, this disadvantage is offset by the advantages
of a lower loss of pressure and the associated lower fan output, as well as a simpler
design. The area underneath the grate is more accessible, which makes the task of
replacing damaged plates easier.

Advantages Disadvantages

Direct Aeration effective plate cooling greater loss of pressure

selective air distribution
greater heating of the combustion
air
greater consumption of electrical
energy
pipelines with seals are required
if one plate is lost the entire row of
plates fails to be effective for
cooling!

Chamber Aeration lower loss of pressure higher plate wear

lower consumption of electrical air channeling
energy formation of »red rivers«
simpler design less heating of the combustion air

Table 2.2-1: Summary of Advantages and Disadvantages.

2.2.2 Grate Plates

Optimized Air Routing The development of new grate plates with a small free exit flow cross-section and hor-

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 2.2 Grate Coolers

izontal exit flow prevents air channelling through the clinker layer. The air flow is only
diverted into a vertical direction in the clinker layer at low speed. Structurally optimized
air routing in the grate plate provides adequate cooling with a reduced amount of air. This
therefore prevents thermal damage to the grate plates.
The grate plates currently used can basically be split into two categories:
 Plates with Horizontal Exit Flow (Fig. ??)
This group also includes the stepped grates with horizontal exit flow that are used as
static preliminary grates.

 Plates with Clinker Boxes (Mulden plates, CFG plates, Omega plates, conventional
jet-ring plates, see Fig. ??)
These plates have clinker boxes, into which the cooling air flows horizontally at high
speed through a narrow gap. The cooling air is diverted in the clinker box and flows
out vertically from the plates into the clinker layer. The horizontal flow of air into the
plate prevents clinker from falling through the grate under normal operating conditions
or even if the flow of cooling air is interrupted. There are also plates with diagonal exit
air flow (jet-stream plates).

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 2 Construction and Operation

Wear Plate wear has been significantly reduced in recent years due to improved plate cooling.
Minimization of grate deflection, for example by providing a central support, particularly
in coolers with high throughputs, has also helped to minimize the wear on the underside
of the plates. The wear and amount of clinker falling through at the sides of the grate
have now been reduced by new side seals (Fig. 2.2-3) that are attached to the grate plate
supports and move with the grate without losing their function during thermal expansion
of the grate.

Figure 2.2-3: Side Seal with Welded Attachment .

2.2.3 Roll and HammerCrushers

Roll and Hammer crushers and are machines for reducing the size of the fully burnt
clinker.

Position New coolers are normally equipped with roll crushers but hammer crushers (see Fig.
2.2-4) are also sometimes used for cost reasons. Although intermediate size reduction of
the clinker after the recuperation zone results in more uniform cooling, roll crushers are
generally installed at the end of the cooler for cost reasons. Positioning a roll crusher in

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 2.2 Grate Coolers

the middle of the cooler requires a more complex crusher cooling system and involves
increasing the overall height of the cooler, particularly as a result of the stepped design.
In this case, the cooler must either be arranged lower down (clinker discharge below the
works level) or the entire kiln system must be constructed at a greater height above the
works level.
Fig. 2.2-4 shows an example of a roll crusher. This crusher consists of air-cooled rolls
driven hydraulically or mechanically. Each roll is equipped with cast crushing rings that
are highly resistant to wear and to temperature.

Figure 2.2-4: Hammer crusher.

At this point of the online course you would see a video showing a roll crusher in use
instead of Fig. 2.2-5.

Figure 2.2-5: Roll Crusher from Claudius Peters AG .

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 2 Construction and Operation

2.2.4 Types of Grate Cooler

Various types of cooler, such as reciprocating grate coolers, pendulum grate coolers and
travelling grate coolers, will be explained below.

Reciprocating Grate Coolers

In reciprocating grate coolers fixed and movable grate plates are installed alternately.
The clinker is pushed towards the cooler outlet by the intermittent horizontal movement
of the movable grate plates. The clinker is continuously broken up, comminuted and
circulated, thereby improving the heat exchange. Roll crushers are also positioned between
the grates (depending on the design) to produce a finer particle-size distribution of the
clinker. This makes it possible to achieve lower cold clinker temperatures.
Some cooler grates are installed with a slight incline, especially in the hot region of the
cooler close to the kiln outlet, in order to assist with clinker transport. This prevents
excessive build-up and coating caused by slow transport of the material (inclined grate
8 coolers with 2 grates (Fig. 2.2-6), horizontal grate coolers, combination grate coolers or
stepped grate coolers).

Figure 2.2-6: An Inclined Grate Cooler with 2 Grates Operating as a Reciprocating Grate .

Pendulum Grate Coolers

In pendulum grate coolers (Fig. 2.2-7) a stable oscillating frame with a grate is placed
on pendulum beams and suspended from laminated spring-steel strips. This counteracts
any bending of the grate. The spring deflection dispenses with the need for support using
movable parts. The wear and amount of clinker falling through at the sides of the grate
are reduced by improved side seals that are fixed to the grate plate supports and also move
with the thermal expansion of the grate without any loss of function.

Travelling Grate Coolers

The design of a travelling grate cooler (Fig. 2.2-8) is comparable with that of a recipro-
cating grate cooler, but the hot clinker is fed onto an endless chain belt that transports the
clinker through the cooler and through which the cooling air flows from below. A crusher
for primary comminution of the cooled clinker is generally positioned downstream of this
belt.

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 2.2 Grate Coolers

9
Figure 2.2-7: Pendulum Grate Cooler .

Figure 2.2-8: Travelling Grate Cooler .

Further Information
The above-mentioned clinker coolers are described in detail in data sheet Vt 8 »Grate
Coolers, Satellite Coolers and Rotary Coolers in the Cement Industry«.

2.2.5 New Generation of Grate Coolers

Already in the early 1990s when a new cooler generation with fixed inlet and modified
grate cooling effect (Coanda effect) was introduced by IKN, considerable improvements
were made in heat recuperation, wear and reliability. In the late 1990s, FLS intro¬duced
the so called SF-Cross-bar cooler. The principal and fundamental change was that the
clinker transport from the cooler inlet to outlet was not done by reciprocating grates but by
reciprocating steel bars across the clinker bed. The major advantage is the cooler aeration
floor below the clinker bed is only exposed to cold clinker creating absolutely no wear.
Due to its design, there is no clinker through fall. The wear on the cross bars is aston-
ishingly low and maintenance can be considered minor. The process functions are also

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 2 Construction and Operation

good due to good clinker distribution, high heat recuperation and easy speed control. A
few years later FLS introduced the so called Multi-Movable Cross-bar cooler based on
the “walking floor" principle already in-troduced in the industry earlier. It offers better
possibilities for improved clinker distribution and cooling. The general technology is well
proven and made the clinker cooler operation quite reliable.
The latest developments focus further on reducing movable and clinker transporting com-
ponents away from the hot clinker. Polysius, for example, introduced the Polytrack clinker
cooler, a horizontal cross-flow cooler. It is a combination of a static aeration floor and a
conveying device positioned separately above it. The conveying elements are shaped like
planks and lie parallel to the direction of transport. The entire plank system moves forward
in the transport direction by one stroke length and carries the material with it. The planks
are then pulled back in separate individual steps. The new cooler type installed proved
to be very reliable, show minimum wear and good heat recuperation. The major advan-
tage of the new designs is that “red rivers" can be almost avoided because the longitudinal
sections and therefore the clinker transport speed can be controlled individually. The new
eta-Cooler introduced by Claudius Peters is using a different transport concept. It is based
10
on the well proven “walking floor" system. The eta-Cooler consists of parallel trans-port
lanes which are moved together in the direction of clinker transport (for-ward stroke) and
individually or alter-natively alternatively in groups backwards (backward stroke). With
the parallel, individually driven and aerated transport lanes, the flow behaviour and mate-
rial speed at the sides can be actively influenced, thereby preventing a red river. The slots
for air supply are integrated in the transport lanes and are protected by non-moving cold
clinker, which form an autogenous protection. All modern clinker coolers of today have
all the following features:
 Heat recuperation exceeds in general 70% and goes up to 80%
 Good clinker distribution
 Less movable, not heat exposed parts
 No clinker fall through
 Low specific cooling air require¬ments of 1.7 to 1.9 Nm3/kg clinker
 Decreased electricity consumption
 Reduced building height
 Quick installation due to modular design
The "eta-cooler®" from Claudius Peters, the "Polytrack Cooler®" from Polysius and the
"Pyrofloor Cooler®" from KHD will be described below as examples of the new genera-
tion of grate coolers.

Eta Cooler ® from Claudius Peters

The Eta cooler® from Claudius Peters starts with an inclined static inlet that widens from
the kiln discharge to the moving reciprocating lanes in order to distribute the clinker (1,000
to 12,000 t/d) optimally over the width of the grate. A continuous protective clinker
layer protects this and all subsequent modules from unnecessary wear. Direct aeration
is achieved through small aeration fields, the air volume being flexibly adjusted by manual
flaps. The subsequent transport system is based on the »walking floor« or pendulum floor
system. The clinker is moved forwards on parallel reciprocating lanes that are individ-
ually hydraulically driven and aerated, and move together on the forward stroke. These
reciprocting lanes are retracted again either individually or in groups. The flow properties
and material speed at the sides can thus be actively influenced in order to counteract »red
river« formation. Hydraulic control systems provide continuous contact-free measurement
of the position of the cylinders in order to ensure that the strokes are of the length required.

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 2.3 Rotary Coolers

The position and configuration of the aeration slots in the reciprocating lanes are based on
the Mulden grate plate principle. The entire cooler floor is aerated. The reciprocating lanes
are sealed by a labyrinth seal in such a way that a dedusting system is not necessary. The
final module is a roll crusher.
At this point in the online course you would see a video by »Claudius Peters«.

Polytrack Cooler ® manufactured by Polysius

The Polytrack cooler® is a combination of a static horizontal aeration floor and a convey-
ing system positioned above it. In contrast to the previous system there is strict separation
here between the functions of transport and aeration. Special sliding elements seal the few
contact zones between stationary and moving cooler components. The transport system
consists of conveying planks driven by hydraulic cylinders installed below the static aer-
ation floor. Each row of planks runs the entire length of the cooler. The variable thrust
speeds of the conveying planks achieve good transverse distribution of the clinker. The
transport planks are moved forward together and are retracted individually. The conveying
speed, the depth of the clinker layer and the clinker throughput are controlled by vary-
11
ing the length and frequency of the conveying thrust. Air is distributed by fixed aeration
elements located between the conveying planks. The large integral chambers are perma-
nently filled with clinker (autogenous wear protection). Air is distributed via a labyrinth
construction of the aeration elements. The Polytrack cooler® has a modular structure like
the Eta cooler® and, if desired, may be provided with a static preliminary grate and also,
owing to its flat structure, an intermediate crusher to intensify the cooling.
At this point in the online course you would see a video by »Polysius«.

Pyrofloor Cooler ® from KHD

At this point in the online course you would see a video by »KHD Humboldt Wedag
GmbH«.

2.3 Rotary Coolers

The rotary cooler consists of a rotary tube at a slight incline of 4 to 7 %. The tube is Structure
mounted on roller stations, has a diameter to length ratio of approx. 1:10 and is provided
with its own drive. An electric motor is used to drive the cooling tube through a pinion and
girth gear at rotational speeds between 0.3 and 3 rpm. The cooling tube is either arranged
as a continuation after the rotary kiln or, if there is less space available, underneath the
rotary kiln facing the opposite direction (Fig. 2.3-1). The cooling tube is equipped with
internal fittings to improve the heat transfer between the clinker and the cooling air (Fig.
2.3-2).
The clinker falls from the edge of the kiln through a drop shaft into the hot region of Operating Principle
the cooler and is then transported to the cooler outlet by the rotational movement of the
cooling tube and its slight incline. However, in contrast to rotary kilns only part of the
rotary cooler is provided with refractory lining, which protects the cooling tube against
excessive heat in the hot region near the kiln outlet. Internal fittings of differing shapes are
provided further along the cooler (Fig. 2.3-2).
The internal fittings carry out the following functions: Purpose of the Internal
Fittings
 they break up the coarse particles

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 2 Construction and Operation

Figure 2.3-1: Rotary Cooler and Rotary Kiln Positioned in Opposite Directions .

12
direction of transport

direction of rotation

Figure 2.3-2: Internal Fittings in a Rotary Cooler .

 they spread the clinker in the cooling air flow

 they circulate the clinker for improved cooling

Advantages and Disadvantages

Advantages Disadvantages

long contact time between air and clinker
(good heat transfer)
simple operation
no dedusting of cooler exhaust air
internal fittings can be replaced individually
difficult to seal (between the kiln and cooler)
heavy recirculation of dust in the cooler
the amount of secondary air is the same as the
amount of cooling air
high wear costs

Table 2.3-1: Advantages and Disadvantages of Rotary Coolers.

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 2.4 Satellite Coolers (Planetary Coolers)

2.4 Satellite Coolers (Planetary Coolers)

Structure and Operating
Principle

13

Figure 2.4-1: Rotary Kiln with a Satellite Cooler.

A satellite cooler (also known as a »planetary cooler«) consists of 9 to 12 individual

cooling tubes attached rigidly to the rotary tube of the kiln (Fig. 2.4-2). The individual
cooling tubes have refractory linings at the front and various internal fittings further along
their lengths (Fig. 2.4-3). The rear portion of the kiln forms the burner tunnel, which is
separated from the burning zone of the rotary tube by a dividing wall. The rotary kiln
burner is mounted on a platform that extends from the rear into the burner tunnel and is
self-supporting. The clinker falls through openings in the kiln shell and into the inlet zones
of the cooling tubes. The openings in a satellite cooler are provided with cross barriers so
that no large lumps of coating, which could cause blockages, can enter the cooler. Satellite
coolers are configured in such a way that when the kiln, and therefore the cooling tube, is
rotated no material falls back into the kiln. The clinker is transported through the cooler
by its rotational movement and slight incline and is discharged onto the clinker transport
system by special discharge scoops that rotate with the cooler.

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 2 Construction and Operation

cooling tube rotary kiln

Figure 2.4-2: Longitudinal Section through a Satellite Cooler .

14

recuperation convection and radiation

zone zone

Figure 2.4-3: Internal Fittings in a Satellite Cooler .

Advantages and Disadvantages

Advantages Disadvantages

lower energy consumption of drive (no
additional drive)
no dedusting of cooler exhaust air needed
uniform flame obtained by dividing the cooling
air between up to 12 cooling tubes
unequal air flow rate with unequal loading of
the cooling tubes
no way of regulating the cooler (rotational
speed)
the amount of secondary air is the same as the
amount of cooling air.
difficult to access for repairs
excessive noise produced by the individual
tubes (overall height) and by the internal
fittings
unequal loading of the cooling tubes may lead
to curvature of the rotary tube

Table 2.4-1: Advantages and Disadvantages of Satellite Coolers.

Rotary coolers and satellite coolers are now no longer the preferred methods of cooling
owing to their high operating costs and susceptibility to mechanical failure.

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 2.5 Other Clinker Coolers

2.5 Other Clinker Coolers

Other examples of special types of clinker cooler include the »twin cooler« from »Poly-
sius«, i.e. a combination of a cooling drum, roll crusher and vibrating grate, and the
»recuperator« with »g-cooler« from »Claudius Peters«.

Twin Cooler from Polysius

The twin cooler (Fig. 2.5-1) was specially developed by »Polysius« for the production of
white cement . It consists of a combination of a cooling drum, roll crusher and vibrating
grate. The cooling drum that rotates on two welded tyres is driven by a circumferential
chain. Its inlet and outlet seals are familiar systems from rotary kilns that have been
adapted to cooling drums. The clinker falling from the kiln is first fed to a cooling drum,
where it is very rapidly cooled with water from 1,400◦C to 600◦ C. Once the clinker has
then passed through a roll crusher (particle size <50 mm) it is cooled further with air on a
vibrating grate. The subsequent cooling of the clinker from 600◦ C to a final temperature
of approx. 100◦C is therefore carried out with air to recover the heat in the clinker for 15
secondary air.

Figure 2.5-1: Diagram of a White Cement Cooler.

Recuperator and g-Cooler from Claudius Peters

The recuperator and g-cooler from »Claudius Peters« combines direct precooling (single
grate cooler), intermediate size reduction, intermediate transport and indirect final cool-
ing in order to achieve a high level of heat recovery, a low final clinker temperature and
largely dust-free exhaust air. The clinker discharge temperature of approx. 450 ◦ C at the
end of the recuperator means that it is necessary to use a roll crusher that comminutes the
oversized material. The roll crusher operates without any friction. The g-cooler is an indi-
rect heat exchanger for granular material in which the clinker moves very slowly (approx.
3 cm/min) through the cooler under the force of gravity (g). Since the air does not come
into direct contact with the clinker (indirect cooling), the exhaust air is free from dust so
no investment or maintenance costs are incurred for exhaust air filter plants.

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 3 Operation and Quality

16

Figure 2.5-2: White Cement Cooler.

3 Operation and Quality

The clinker cooler represents a central component in the clinker production process and
used to be most difficult to optimize. It influences the kiln operation positively or nega-
tively depending on its control and adjustment, it impacts the fuel efficiency considerably
depending on its heat recuperation efficiency and especially determines the reliability of
the entire kiln system due to its complex functions and high thermal load. Overall produc-
tion cost can substantially be impacted by the clinker cooler and its functional reli-ability.
Considerable efforts in development of more reliable and efficient cooler technology were
invested by most cement system suppliers with impressive improvements achieved espe-
cially in material wear and system reliability.

Factors Affecting Cooler Operation

 Control indicators (undergreate pressure; kiln hood pressure, Cooling airflow;etc.)
 Motivation, qualifications and operational knowledge of personnel
 Regular servicing and inspection of the machines and plants
 Preventive maintenance
 Provision of the spare parts and wearing parts required
 Tidiness and cleanliness of the workplace
 Guarantee of industrial and operational safety
The high demands placed on the quality of the cement clinker and on environmental com-
patibility mean that the rotary kiln and clinker cooler must be operated uniformly and that
the optimal rate of cooling must be achieved. Control systems are used for this and are

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operated via the process control system.
Main control parameters of a grate cooler are:
 Undergrate pressure (bed resistance)
Undergrate pressure is a reflection of bed resistance and is used as the indicator of resis-
tance for control purposes. Bed resistance is the resistance to airflow created by a layer of
clinker on the cooler grate and is monitored to ensure that it does not become greater than
the capabilities of the cooling fans.
 Kiln hood pressure
Cooler exhaust fan speed is adjusted to regulate the kiln hood pressure in order to maintain
a constant draft setpoint. As the hood draft becomes more positive the cooler vent fan
speed must be increased to maintain the negative setpoint.
 Cooling airflow
Airflow control is complementary to undergrate pressure and should maintain a constant
specific volume of cooling air to the cooler independent of the undergrate pressure. Cor-
rect airflow distribution improves thermal efficiency and prevents damage to grates due to
overheating. 17
 Secondary & tertiary air temperatures
Secondary and tertiary air temperatures are a result of cooler efficiency. Maximizing sec-
ondary air temperature means achieving efficient heat transfer between clinker and cooling
air. A maximum amount of heat recovered from the clinker increases fuel efficiency and
improves the stability of the kiln system.
Secondary control parameters of a grate cooler are:
 Grate plate temperature
Monitoring of grate plate temperatures via thermocouples attached to the plates gives a
good indication of cooler performance. It is a guideline temperature used to determine
airflow rates and/or grate speeds.
 Clinker discharge temperature
A guideline temperature used to determine the amount of cooling airflow needed and/or
the speed at which to run the cooler grate. Low clinker temperatures are desired at the
discharge of the cooler, which ensure maximum heat recuperation from the cooling system.

Grate Cooler Upset Conditions

"Red river" A "red river" is formed from the segregation of fines and coarse clinker parti-
cles from the kiln outlet. The coarse clinker particles discharge earlier than the fines from
the kiln resulting in a flow of fine material down one side of the grate cooler.
Blow Through or "Geyser" Effect The "Geyser" effect is experienced when too much
air is placed on the cooler grate and air blows through the clinker bed.
Snowman Formation A snowman formation is a mound of molten material within the
cooler inlet which disturbs the airflow pattern to the kiln resulting in unstable kiln condi-
tions.
High Grate Plate Temperatures High grate temperatures are experienced when kiln up-
set conditions are present and fine raw feed enters the cooler during a kiln "push" or coating
fall.

Factors Affecting Product Quality

The cooler of the kiln system performs two central functions:
 it cools the hot clinker from the kiln

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Research Institute of the Cement Industry
 4 Health and Safety Practices

 it recovers the heat (recuperation) of the thermal energy contained in the clinker for
the kiln system and, if necessary, also utilizes the cooler exhaust air
A rapid rate of cooling plays a vital role for the clinker quality in the cooling range above
1,200◦ C.

Importance of Rapid
 The alite phase (C3S) remains stable (otherwise it breaks down into belite and free
Cooling lime).
 Finer C3A and C4AF crystals are formed (C3A reacts more slowly with mixing water).
 A high MgO content has a less impact on soundness.
 Resistance to grinding is lower since the crystals are generally smaller.
Tests have shown that the workability period of cements containing rapidly cooled clinker
is longer than that of cements containing clinker that has been cooled more slowly. In
addition, the 28 d strength is lower with clinker that has been cooled slowly. This effect is
intensified when the ratio of C3A to C4AF is greater than 1. The rate of cooling no longer
affects the product quality below 1,200◦ C. However, the outlet temperature of the clinker
is of considerable importance for the selection of subsequent transport equipment and for
18 the cement mill operation.
Recuperation Recuperation of the heat contained in the clinker is very important for the quality of
clinker burning. This means that the secondary air for combustion in the kiln system is pre-
heated to the highest possible temperature by the hot clinker. The cooler operation should
therefore be optimized with respect to this factor, among others. It should be noted that, in
principle, the higher the temperature of the secondary air and the greater the amounts of
secondary and tertiary air removed from the cooler, the better the recuperation of a cooler.
Consequently, a reduction in the amounts of false air and primary air has a positive effect
on cooler efficiency.

4 Health and Safety Practices

Industrial Safety
Machines and equipment in a cooler pose the following basic risks:
 mechanical risks, for example squeezing, striking, shearing, pulling
 electrical risks, for example approach to or contact with live parts, electrostatic charges
 risks caused by physical effects, for example noise, vibration
 falling from a great height
 skin contact with dust that irritates the skin
 working with air-blast equipment, Cardox (CO2) cleaning systems and high-pressure
water cleaning systems
SafetyMeasures There is a wide range of safety measures for protecting equipment and people. The main
safety measures are as follows:
 covering and enclosing dangerous machine parts
 protection against falling from a height
 acoustic and visual alarms
 safety interlocks for start-up and breakdown
 filling, pressure and temperature monitors
 emergency shutdown devices
 depressurizing the air-blast equipment when entering the cooler!
Requirements for Protective Measures:
 protective coverings must be stable and must only be removable with the aid of tools.
 it must not be possible to easily avoid them or to make them ineffective.

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Research Institute of the Cement Industry
 there must be an adequate distance from the danger area.
 the monitoring of work operations should not be restricted more than necessary.
 additional risks must not materialize.
 isolating safety devices must ensure that machines cannot be switched on inadver-
tently.
Common means of communication include: Means
ofCommunication
 warning and information signs
 signalling of hazards (visual, acoustic)
 camera monitoring
 automatic alarm triggers
 radio contact
 workstations within visual range
 regular training and instruction

Health protection
Consistent application of health and safety practices provides personal protection for the
19
workers in a cement works. When working on clinker coolers the following measures
should be taken to ensure the health of the personnel:
 noise protection when working in noisy plants
 provision and use of personal protective equipment
 preventive inspections carried out by staff (night work, noise inspections)
 drafting of risk analyses

5 Wear, Maintenance and Inspection

Wear and Corrosion
Wear is caused by friction, shock, impact, heat or even by chemical reactions. Wear can
be reduced by the appropriate selection of materials and the use of lubricants.
Selection of Materials
 wear-resistant and heat-resistant materials, for example
 cooler plates of varying grades,
 crusher elements, cooler side plates, lifting scoops...
 materials with improved sliding properties, for example
 balance rollers, oscillating frame supports
 refractory lining: use heat-treated precast elements as it is very difficult to heat the
cooler.
 protection of the sheet steel housing against excessive heating.
 protection against abrasion.
Use of Lubricants
 improves sliding properties
 absorbs pressure
 provides temperature resistance
 protects against corrosion

Maintenance and Inspection

During normal operation maintenance and inspection of the cooler is confined to the
following key points:

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Research Institute of the Cement Industry
 6 Environmental Protection

 visual check of the hot regions for any scorch marks (an indication of refractory dam-
age)
 checking of the emptying chambers for frequency of emptying (defective grate plates)
 regular checking to ensure smooth material flow (before the crusher)
 checking that the air-blast equipment is functioning
 checking the oscillating frame bearings and the grate drive
 checking the mechanical state of attachment systems (satellite coolers)
 checking seals for tightness
 checking for any leaks in the hydraulic and pneumatic systems
A large number of units are equipped with self-monitoring devices (switches, warning de-
vices and displays). These make it possible to detect any deviations from normal operating
values in good time and therefore allow operators to carry out selective checks. Key aids
include:
 compilation of fault and breakdown reports
 distribution of checklists for checking key areas
20  compilation of inspection lists and repair plans for preventive maintenance

6 Environmental Protection
Environmental Protection
Protection against Noise and dust may be produced during the operation of clinker coolers.
Noise and Dust
The dust produced can be removed from the exhaust air of the cooler by using prelim-
Dust
inary dedusting equipment (cyclones, multiclones) and by using filters. If electrostatic
precipitators are used then the exhaust air must first be conditioned by water injection.
Noise The fans are sources of noise emissions in clinker coolers. The operation of satellite cool-
ers is particularly noisy. Noise can be reduced by measures such as the use of sound
absorbers (fans) and the use of soundproof walls and hoods. It should be noted that uni-
form kiln operation results, in principle, in the lowest emissions. Cooler operation must
therefore also be uniform.
Energy Consumption Energy saving, as an environmental protection measure, is achieved by:
 using waste heat for combined drying and grinding
 using waste heat for heating (district heating, heat transfer oil heating)
 conversion of heat into electricity

Factors Affecting Energy Consumption

Modern plants are almost exclusively fitted with grate coolers. Developments in the field
of grate cooler technology have led to a significant improvement in the thermal efficiency
and availability of plants. Many clinker coolers have been modernized with the aim of
achieving higher combustion air temperatures and lower clinker temperatures with a re-
duced volumes of cooling air.
Power Consumption of electrical energy is dependent on:
 the choice of the cooler system (independent drive, separate cooler air fan)
 the clinker temperature required on discharge (more cooling air may be required)
 amount of exhaust cooler air (greater fan output)
Heat Thermal energy can be used by:
 high secondary air temperatures to save heat
 reduction of heat loss through the wall by using lining

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Research Institute of the Cement Industry
 elimination of false air

7 Questions on Course LB 3.6 – Clinker Coolers

You can test your knowledge by answering the following questions.

Question 7.0 A:
1. What is the purpose of clinker coolers?
2. What types of clinker cooler are there?
3. What is the purpose of internal fittings in satellite coolers?
4. What types of grate cooler are there?
5. What effect does the rate of cooling of clinker have on clinker properties?
6. What inspections should be carried out on clinker coolers?
7. What causes wear in clinker coolers? 21
8. How can wear in clinker coolers be minimized?
9. What are the possible ways of utilizing energy in clinker coolers?
10. Which harmful emissions are produced when operating clinker coolers?
11. Name some suitable measures for reducing these emissions
12. How is the health of the personnel protected?
13. Name key safety measures which should be taken
Solutions see p. 22

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Research Institute of the Cement Industry
 7 Questions on Course LB 3.6 – Clinker Coolers

Solutions
Solution for 7.0 A:
1. Clinker coolers: – cool the clinker in order to stabilize the melt phases in ac-
cordance with a set temperature profile – heat the secondary/tertiary air by heat
transfer between the clinker and air
2. Types of clinker cooler: – rotary coolers – satellite coolers – grate coolers
3. Internal fittings in satellite coolers: – cross barriers in the inlet region prevent
blockages caused by large lumps of coating – internal fittings transport and circu-
late the clinker to ensure better cooling
4. Examples of grate coolers include: – pendulum grate coolers – travelling grate
coolers – reciprocating grate coolers
5. – a rapid rate of cooling stabilizes the melt phases – with a slow rate of cooling
the C3S (alite) breaks down into C2S
6. Inspections of clinker coolers: – visual check of the hot regions (scorch marks
22 caused by refractory damage) – checking the emptying chambers to determine the
frequency of emptying (defective grate plates) – regular checking of the material
flow before the crusher – checking that the air-blast equipment is functioning –
checking for any leaks in pneumatic and hydraulic ducts and systems – checking
seals for tightness
7. Wear in clinker coolers: – friction – shock – impact – heat – chemical reactions
8. Wear reduction in clinker coolers: – wear-resistant and heat-resistant materials –
materials with improved sliding properties – protection of the steel structure by
refractory material against thermal damage – protection against abrasion
9. Energy utilization in clinker coolers: – use of waste heat for drying – use of waste
heat for heating systems – conversion of waste heat into electricity
10. Emissions produced by clinker coolers: – dust – noise
11. Measures for reducing emissions: – dedusting in filters – use of preliminary de-
dusting equipment (cyclones) – use of soundproof walls
12. Health protection of the personnel: – noise protection for very noisy plants –
provision of personal protective equipment – preventive inspections carried out by
staff – drafting of a risk analysis
13. The main safety measures are as follows: – covering and enclosing dangerous ma-
chine parts – protection against falling from a height – acoustic and visual alarms
– safety interlocks for start-up and breakdown – filling, pressure and temperature
monitors – emergency shutdown devices – depressurizing the air-blast equipment
when entering the cooler
Questions see p. 21

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Research Institute of the Cement Industry
Glossary
calciner
Suspension flow reactor in which the calcination reaction of the kiln meal takes place; industrial equipment for
reducing nitrogen monoxide by staged combustion.
hammer crusher
Equipment for reducing the size of coarse material; it uses the impact force of hammers attached to a rotor for
comminution.
secondary air
Heated air from the cooler that serves as additional air for the rotary kiln burner
sintering
Fusion of a material, generally without melting it
tertiary air
Hot air from the cooler that is carried by the ’tertiary air duct’ to the calciner, where it is used as combustion air.
white cement
Very light-coloured Portland cement with a low iron oxide content; production is complex since the hot clinker
must be cooled extremely quickly
23

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Research Institute of the Cement Industry
 Index

C
calciner 1

H
hammer crusher 6

S
secondary air 1
sintering 1

T
tertiary air 1

W
white cement 15

24

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Research Institute of the Cement Industry