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Modernizacion Enfriador de Clinker (Ingles)
Modernizacion Enfriador de Clinker (Ingles)
Modernizacion Enfriador de Clinker (Ingles)
February 2019
1. Summary
SATAREM completed the engineering to modernize a 2,100 TPD Folax cooler for a cement plant in
Latin America. The use of software tools combined with a long history in modification of clinker
coolers allowed to create an innovative solution that will allow to improve kiln system
performance while considering restrictions of space, existing equipment and on-site process
conditions. Modified cooler will reduce cooler downtime by 50%, reduce heat consumption by 5%
and increase output but 7%.
Initially, SATAREM carried out an on-site diagnostic, which allowed identifying operational and
design problems. Regarding operational problems it was evidenced, for example, that system had
frequent "red river" and clinker outlet temperature around 200°C. On other hand, in relation to
mechanical design, there were frequent damages to kiln seal due to static inlet installed near kiln
nose ring, burning to cooler plates and frequent stoppages due to failures on mechanical drive. All
above elements cause loss of clinker production and increase of heat consumption.
complete modification will be implemented keeping existing casing and most of fans, which will
allow considerable savings for dismantling, assembly and civil works, as well as a reduction in
downtime due to cooler project implementation.
On "bull nose" area problems of excessive wear due to secondary air high speed are common,
leading to deterioration and premature falling of refractory. To decrease speed of secondary air
towards kiln, first section (static inlet and first mobile grate) was moved downwards, leveling it
with second section (second mobile grate).
When lowering fixed grate and first mobile grate this modification solves two problems: 1.
Increasing hot gases passage area at "bull nose" therefore reducing gases speed by 21.2% and 2.
Eliminating premature damage of kiln seal by increasing distance between kiln nose and clinker
bed.
Illustration 1. Current Flow ratel (14.05 m/s) Illustration 2. Flow rate when lowering grate (11.07
m/s)
The improved design of SATAREM cooler includes some key elements that allow to increase both
efficiency of heat recovery and clinker transport, these elements are:
Hydraulic drive:
For this cooler it is proposed to install a
hydraulic unit to replace the old-design
mechanical units. Hydraulic drives are more
reliable and requires almost no maintenance,
thus improving cooler running factor.
6. Results
Based on simulation carried out and based on other modifications made by SATAREM Group, the
new system:
Improves heat recovery efficiency by increasing secondary air temperature from 810 to 900°C.
Guarantees clinker outlet temperature at 80 ° C + T ambient.
Improves running factor by reducing cooler stops by 50% at least.
Allows increasing, in a sustained way, kiln output to 2,300 TPD.