1. PAINPOINT DRIVEN OPENING

Managing the final stage of clinker cooling is a critical bottleneck with direct consequences for plant profitability. Inefficient clinker cooler operation leads to excessive heat loss, reducing thermal recovery for your preheater and calciner systems. Unstable cooling results in clinker quality inconsistencies, causing downstream grinding inefficiencies and potential cement performance issues. Frequent maintenance interventions for grates, hydraulics, and fans create unplanned downtime, while highpressure fans drive significant electrical energy consumption. Are you facing rising energy costs per ton of clinker? Is your cooler refractory and mechanical component lifespan shorter than expected? The solution lies in optimizing this essential link between the kiln and the finish mill.

2. PRODUCT OVERVIEW: Grate Clinker Cooler

The Grate Clinker Cooler is a critical heat recovery and conditioning machine installed directly after the rotary kiln discharge. Its primary function is to rapidly reduce clinker temperature from approximately 1200°C to below 100°C for safe handling and storage, while simultaneously recovering and supplying hot air to the kiln and calciner.

Operational Workflow:
1. Inlet & Distribution: Redhot clinker from the kiln enters via an inlet hopper and is evenly distributed across the full width of the stationary inlet grate.
2. Grate Transport & Primary Cooling: Reciprocating grates convey the clinker bed forward. Highpressure cooling air is forced upward through the grate plates and clinker layer, providing intensive quenching.
3. Heat Recovery: A significant portion of the heated cooling air is directed as secondary air to the kiln combustion zone and as tertiary air to the calciner, directly improving kiln fuel efficiency.
4. Final Cooling & Discharge: The clinker moves through subsequent grate zones with controlled air volumes for final cooling before being discharged via a drag chain or roller crusher at the cooler outlet.

Application Scope & Limitations:
Scope: Designed for dryprocess cement plants with rotary kilns, suitable for capacities from 1,500 to over 12,000 TPD. Effective for a wide range of raw mix compositions.
Limitations: Performance is highly dependent on consistent clinker granulometry; extreme variations can lead to uneven air distribution (piping). Not designed for wet process kilns or as a standalone unit without integrated heat recovery ducting.

3. CORE FEATURES

Modular Grate Plate System | Technical Basis: Highchromium cast alloy design with optimized aperture geometry | Operational Benefit: Exceptional resistance to thermal shock and abrasion, leading to plate lifetimes exceeding 5 years under normal conditions | ROI Impact: Reduces spare parts inventory cost by up to 30% and major maintenance downtime intervals.

Adaptive Air Flow Control | Technical Basis: Multiple independently controlled fan zones with PLCmanaged dampers | Operational Benefit: Allows precise air volume adjustment per cooling zone based on realtime clinker bed conditions and temperature feedback | ROI Impact: Improves heat recovery efficiency by 35%, directly reducing specific fuel consumption.

Hydraulic Reciprocating Drive | Technical Basis: Electrohydraulic drive system with proportional valves for smooth motion control | Operational Benefit: Provides infinitely variable stroke length and speed, enabling optimal clinker bed movement without turbulence or dust generation | ROI Impact: Enhives cooler stability, reduces electrical consumption of drive system by up to 15% compared to fixedspeed systems.

Advanced Sealing System | Technical Basis: Labyrinth seals combined with pressurized sealing air chambers at grate edges | Operational Benefit: Minimizes false air infiltration into the hot air recuperation ducts | ROI Impact: Increases secondary/tertiary air temperature by an average of 2030°C, improving overall kiln system thermal efficiency.

Integrated Condition Monitoring | Technical Basis: Thermocouples embedded in grate plates and bearing sensors on fan motors | Operational Benefit: Provides early warning of potential failures like red rivers or mechanical issues through centralized control room alerts | ROI Impact: Enables predictive maintenance scheduling, preventing catastrophic failures that can cause 714 days of production loss.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Grate Clinker Cooler Solution | Advantage (% Improvement) |
| : | : | : | : |
| Specific Cooling Air Volume (Nm³/kgcli) | ~2.0 2.2 Nm³/kgcli| ≤1.8 Nm³/kgcli| Up to 10% reduction |
| Heat Recovery Efficiency (%)| ~70 72%| >74%| ~35% increase |
| Grate Plate Service Life (months) | ~36 48 months| >60 months| ~25% longer lifespan |
| Electrical Energy Consumption (kWh/tcli) | ~6 7 kWh/tcli| ~5 5.5 kWh/tcli| Up to 15% reduction |
| Clinker Outlet Temperature (°C) Ambient +80100°C| Ambient +65°C max.| More consistent grindability |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,500 to 10,000 Tons Per Day (TPD) of clinker.
Power Requirements: Total connected load varies by size; e.g., a 5,000 TPD cooler requires approximately 8001000 kW for all fans and drives (3phase, voltage as per plant specification).
Material Specifications: Grate plates cast in ZCr26Ni12 highchromium alloy; side liners in abrasionresistant steel; housing constructed from carbon steel with internal refractory lining in hot zones.
Physical Dimensions (Example for 5k TPD): Overall length ~35m; width ~6m; height from ground level ~10m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dustladen environment compatible.

6. APPLICATION SCENARIOS

Plant Capacity Upgrade Challenge Challenge A midsized plant increased kiln capacity by 20%, but the existing cooler became a bottleneck, causing high outlet temperatures and reduced kiln efficiency. Solution Implementation A retrofit involved installing wider modular grate sections,a new highefficiency hydraulic drive,and upgraded highpressure fans. Results Quantifiable Outcomes Clinker throughput matched new kiln capacity.outlet temperature stabilized below+75°C,and secondary air temperature increased by45°C,saving1$5%in specific fuel consumption

High Maintenance Cost Scenario Challenge A plant faced annual downtime exceeding300 hours due to frequent grate plate changesand seal failures on an older cooler model. Solution Implementation Replacement with our modular grate system featuringthe advanced sealing technologyand integrated condition monitoring package. Results Quantifiable Outcomes Grate plate replacement interval extendedfrom18to54 months.Predictive monitoring reduced unplanned stopsby80%.Total annual maintenance hours relatedto the cooler fell by over60%

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on capacity(TPD)and specific configuration requirements:
Base Configuration Tier Includes core cooler structure,grate modulesstandard drives,and basic control integration
Optional Features Available upgrades include advanced process control software packageshighefficiency fan impellers,and premium instrumentation suites
Service Packages We offer structured plansfrom annual inspectionand parts kits too comprehensive longterm service agreements(LTSAs)covering all mechanicaland electrical components
Financing Options Flexible capital expenditure solutions are available including traditional purchase equipment leasingand performancelinked financing structures where payments can be partially alignedwith verified efficiency gains

8 FAQ

Q What levelof modificationis requiredto retrofit this coolerto an existingkiln line?
A Retrofit engineeringis a core competency.The interface at the kiln hoodis carefully designedto match existing geometry Minimal disruptionto foundation structuresis targetedwith most work occurringduring planned major kiln shutdowns

Q How doesthe adaptive airflowcontrol impactoperator workload?
A The system operatesautomaticallybasedon set parametersand feedbackloops reducingthe needfor manual damper adjustmentsby operators This allows personnelto focuson monitoringoverall system healthratherthan constant tuning

Q Are spare parts forgrate plates standardizedor custom?
A We utilizea modular designwith standardizedinterchangeableplate sizeswithin eachcooler model This drastically simplifiesinventory managementfor plantsand ensuresglobal availabilityof critical wear parts

Q Whatisthe typicalinstallationand commissioningtimelinefor anew greenfieldcooler?
A Fora full greenfield installationmechanical erectionrequiresapproximately1620 weeksfollowing foundation readiness Electricaland automation integrationadds46 weeks Commissioningand performance guaranteetesting typically takes34 weeks

Q Do you provideperformance guarantees?
A Yes we offer contractual guaranteeson key metricsincluding specificair volumeclinker outlet temperature heat recovery efficiencyand total power consumption subjectto agreedupon baseline conditions