1. PYNPUNT GEDREWE OPENING

Managing the final stage of clinker cooling presents persistent operational challenges that directly impact plant profitability. Inefficient cooling leads to hightemperature clinker entering the conveyor system, accelerating belt wear and creating safety hazards for personnel. Excessive fan power consumption drives up operational costs, while inconsistent quenching results in poor cement quality and potential mill inefficiencies. Unplanned maintenance due to refractory damage or mechanical failure in the cooler causes costly kiln downtime.

Are you facing rising energy costs per ton of clinker? Is your maintenance team constantly addressing downstream equipment damage from hot clinker? Are you achieving optimal cement quality and mill performance from your cooled clinker? A highperformance grate cooler is engineered to address these exact issues.

2. PRODUK OORSIG

Die reciprocating grate cooler is a critical heat recovery and quenching machine installed at the kiln discharge. Its primary function is to rapidly reduce clinker temperature from approximately 1200°C to below 100°C for safe handling and grinding, while recovering thermal energy for process optimization.

Operasionele werkvloei:
1. Verspreiding: Hot clinker from the kiln is evenly distributed across the full width of the stationary inlet grate.
2. Vervoer & Quenching: Reciprocating grates move the clinker bed toward the discharge end while controlled volumes of ambient air are forced upward through the bed.
3. Hitteherwinning: Hightemperature exhaust air (ongeveer. 300400°C) is directed to the kiln or precalciner as secondary/tertiary air.
4. Verkoeling & Ontslag: Further cooling with ambient air occurs in subsequent compartments before clinker is discharged at a stable, low temperature.
5. Dust Handling: Fines are collected via drag chain conveyors beneath the grate.

Toepassingsomvang & Beperkings:
This equipment is designed for dryprocess cement plants with rotary kilns. Optimal performance requires consistent clinker granulometry and controlled kiln feed chemistry. It is not suitable for wetprocess plants or for cooling materials with significantly different thermal or physical properties than cement clinker.

3. KERNKENMERKE

Grate Plate Design | Tegniese basis: Highchrome, alloyed castings with optimized venting geometry | Bedryfsvoordeel: Exceptional resistance to thermal shock and abrasion, ensuring stable airflow distribution and extended service life | ROI impak: Reduces replacement part costs by up to 30% and minimizes downtime for plate changes

Modular Compartmentalization | Tegniese basis: Independently controlled air chambers with dedicated fans and dampers | Bedryfsvoordeel: Allows precise air volume adjustment across each cooling zone for optimal heat transfer based on realtime bed conditions | ROI impak: Improves heat recovery efficiency by 510%, die oond se brandstofverbruik direk verminder

Advanced Drive System | Tegniese basis: Hydraulic or electromechanical drives with frequency control and load monitoring | Bedryfsvoordeel: Provides smooth, adjustable grate movement, prevents bed disturbance ("snowplowing"), and protects against overloads | ROI impak: Enhances operational stability, reduces mechanical stress failures, en verlaag spesifieke kragverbruik

Retractable Air Tightness Seals | Tegniese basis: Springloaded sealing strips that automatically adjust to wear on moving grates | Bedryfsvoordeel: Maintains highpressure sealing between moving and stationary parts, minimizing air leakage | ROI impak: Improves fan efficiency, reducing electrical power waste by an estimated 815%

Integrated Process Control Interface | Tegniese basis: Standardized communication protocols (bv., OPC UA) linking cooler sensors to plant DCS | Bedryfsvoordeel: Enables centralized monitoring of temperatures, druk, and drive loads for predictive maintenance scheduling | ROI impak: Facilitates proactive interventions, preventing unplanned stoppages that can cost over $50k per day in lost production

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard | Our Grate Cooler Solution | Voordeel (% verbetering) |
| : | : | : | : |
| Klinker Uitlaat temperatuur | ~120°C + Ambient | < 100°C + Ambient | Tot 25% laer |
| Heat Recovery Efficiency (Secondary Air Temp.)| ~900 1000°C| 1050 1150°C| ~1015% higher |
| Spesifieke kragverbruik (kWh/tklinker) | 6.5 8.5 kWh/t| 5.0 6.0 kWh/t| ~2025% reduction |
| Roosterplaat Dienslewe (in abrasive zones) | 1218 maande| 2430 maande| ~80100% longer |
| Operasionele Beskikbaarheid (beplande stilhouplekke uitgesluit) | 96% |>4 persentasiepunte |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 1,500 aan 12,000 ton per dag (TPD) of clinker.
Kragvereistes: Total installed fan power varies by capacity; bv., a 5,000 TPD unit requires approximately 8001000 kW totale gekoppelde las.
Materiaalspesifikasies: Grate plates cast from GX40CrNiSi275 or equivalent highchrome alloy; side liners in wearresistant steel; housing in carbon steel with internal refractory lining in highheat zones.
Fisiese afmetings: Length scales with capacity; a standard module width is ~2.8m. A midrange unit may be ~25m L x ~6m W x ~8m H.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C; dust concentration in cooling air up to <50 g/Nm³.

6. TOEPASSINGSSCENARIO'S

Plant Capacity Upgrade Challenge

A plant aimed to increase kiln output by 20% but was constrained by an existing cooler causing bottlenecks and high temperatures.

Modernization of Legacy Cooler

An older planetary cooler suffered from frequent breakdowns, poor heat recovery (<850°C secondary air), and inconsistent final clinker temperature.

Resultate

The new modular grate cooler installation matched increased throughput while lowering final clinker temperature by over °40C compared to previous peaks.

Resultate

The retrofit included new grate modules, highefficiency fans, and upgraded controls within the existing footprint.

Resultate

Secondary air temperature increased consistently above °1000C improving specific fuel consumption by .9%. Maintenance costs dropped %60 jaar oor jaar.

7 KOMMERSIËLE OORWEGINGS

Pricing for a complete grate cooler system is projectspecific based on required capacity customization site conditions ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors ancillaries like dust collectors .

Prysvlakke: Budgetary ranges are typically categorized by capacity Small ( tpd ) .

Opsionele kenmerke: Upgraded instrumentation packages advanced refractory designs special alloys for highly corrosive feedstocks redundant drive systems .

Dienspakkette: Threetiered offerings are available:
1 Basic commissioning spares .
2 Comprehensive annual inspection vibration analysis wear part monitoring .
3 Fullservice contract including performance guarantees preventive maintenance parts supply .

Finansieringsopsies: Equipment financing operating leases projectbased leasing structures are available subject to credit approval often structured over a year term aligned with projected savings .

8 Gereelde vrae

What level of modification is required to integrate this cooler with our existing kiln discharge?
Integration engineering includes detailed interface design for the kiln hood transition area foundation modifications if necessary ductwork routing Our team conducts full site surveys prior proposal

How does this equipment handle variations in clinker size or "rooi rivier" voorwaardes?
The compartmentalized airflow system allows operators increase pressure specific zones counteract red channeling The robust grate design withstands thermal cycling while maintaining bed distribution

Can we expect an immediate reduction electrical consumption after installation?
Field data shows immediate reduction specific fan power due higher efficiency fans reduced leakage Longterm savings accumulate through lower maintenance reduced downstream equipment wear

What typical warranty period what does cover?
Standard warranty covers manufacturing defects materials workmanship key components years Wear parts plates seals have separate prorated warranty terms Extended warranties available purchase

How long does installation commissioning typically take major replacement project?
For greenfield project schedule integrated into overall plant construction brownfield replacement typical outage window weeks including demolition new foundation work erection commissioning Critical path planning minimizes total kiln downtime