Objective
In rotary kiln cement plants, much of the heat leaving the rotary kiln with the clinker is recuperated in the downstream clinker cooler.
In the reciprocation grate coolers used until now in rotary kiln cement plants, the bed depth of the clinker material to be cooled in the cooler was limited, because the material has a tendency to agglomerate due to its stickiness. This tendency was to be prevented in this project be redesigning the cooler plates and thus enabling the targeted blowing of varying quantities of cooling air into individual areas of the cooler. The clinker bed depth can then be gradually increased as a function of the improved cooling.
The surface of the clinker to be cooled is to be enlarged by recrushing it after passing through roughly half the length of the cooler, thus improving the heat exchange with the cooling air.
Operating experience to date shows that the redesigned clinker cooler has high availability and low maintenance requirements comparable to conventional grate coolers.
The balance investigations result in an average cooler efficiency of 70, 9 %. The individual values of 6 separate investigations fluctuated between 68,0 % and 75, 2 %. Fluctuations of this magnitude are not unusual, because the operation of a clinker cooler is determined not only by the process engineering design but, above all, also by the clinker granulometry. This factor is, in turn, heavily influenced by fluctuations in the raw material composition and the resulting fluctuations in kiln operation. The interaction between kiln operation and clinker (efficiency) must always be viewed as a dynamic process, and not as a static unit.
It was shown that the targeted cooler efficiency of 70 % was exceeded, at 70,9 %. Presupposing that energy savings of 4 kcal/kg clinker, equivalent to 16,7 kJ/kg clinker, are obtained forevery 1 % increase in cooler efficiency, this results in total energy savings or roughly 115 kJ/kg clinker due to the efficiency increase. Thus, the targeted energy savings of 100 kJ/kg clinker are clearly exceeded.
This results in a higher volumetric flow of secondary air, i.e. more preheated combustion air is fed to the kiln.
The clinker outlet temperature is about 30 deg. C higher than that guaranteed by the plant supplier, but considerably lower than in conventional grate coolers. This temperature could be reduced by supplying a greater quantity of air to the cooler but only at the cost of an increased quantity of exhaust air from the cooler and, thus, an increased energy consumption of the exhaust air fans.
The characteristic feature is the step-by-step increase in the height of the material layer in a cement clinker cooler over the length of the cooler. This both prevents agglomeration of the clinker in the first part of the cooler and also brings about an improvement in recuperation in the second part of the cooler.
The improved recuperation in this cooler yields direct savings on thermal energy which would otherwise have to be supplied in the form of fossil fuels. This results in a corresponding reduction in C02 emission.
The construction of the new plant involves two innovative sub-projects - the present project related to redesigning the clinker cooler, and another Thermie project (IN./00174/91/DE/..) related to the installation of a 6-stage cyclone preheater.
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Coordinator
89077 ULM
Germany
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