1. PAINPOINT DRIVE NOLEING

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, Гидаан бүхий зургийн өрөө, and fans create unplanned downtime, while highpressure fans drive significant electrical energy consumption. Та нэг тонн чулуунцарт ногдох эрчим хүчний зардал нэмэгдэж байна уу?? 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. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ: 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.

Үйл ажиллагааны ажлын урсгал:
1. Inlet & Хувиарилалт: 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. Дулаан сэргээх: 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. Эцсийн хөргөлт & Ахах: 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.

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

3. ҮНДСЭН ОНЦЛОГ

Модульчлагдсан сараалжтай хавтан систем | Техникийн үндэслэл: Highchromium cast alloy design with optimized aperture geometry | Үйл ажиллагааны ашиг тус: Дулааны цохилт, элэгдэлд тэсвэртэй, leading to plate lifetimes exceeding 5 years under normal conditions | ROI нөлөө: Сэлбэгийн бараа материалын өртгийг хүртэл бууруулна 30% and major maintenance downtime intervals.

Adaptive Air Flow Control | Техникийн үндэслэл: Multiple independently controlled fan zones with PLCmanaged dampers | Үйл ажиллагааны ашиг тус: Allows precise air volume adjustment per cooling zone based on realtime clinker bed conditions and temperature feedback | ROI нөлөө: Дулаан сэргээх үр ашгийг сайжруулна 35%, directly reducing specific fuel consumption.

Hydraulic Reciprocating Drive | Техникийн үндэслэл: Electrohydraulic drive system with proportional valves for smooth motion control | Үйл ажиллагааны ашиг тус: Provides infinitely variable stroke length and speed, enabling optimal clinker bed movement without turbulence or dust generation | ROI нөлөө: Enhives cooler stability, reduces electrical consumption of drive system by up to 15% тогтмол хурдны системтэй харьцуулахад.

Advanced Sealing System | Техникийн үндэслэл: Labyrinth seals combined with pressurized sealing air chambers at grate edges | Үйл ажиллагааны ашиг тус: Minimizes false air infiltration into the hot air recuperation ducts | ROI нөлөө: Increases secondary/tertiary air temperature by an average of 2030°C, improving overall kiln system thermal efficiency.

Нөхцөл байдлын нэгдсэн хяналт | Техникийн үндэслэл: Thermocouples embedded in grate plates and bearing sensors on fan motors | Үйл ажиллагааны ашиг тус: Provides early warning of potential failures like red rivers or mechanical issues through centralized control room alerts | ROI нөлөө: Урьдчилан таамагласан засвар үйлчилгээний хуваарийг идэвхжүүлдэг, preventing catastrophic failures that can cause 714 days of production loss.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт жишиг | Our Grate Clinker Cooler Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Specific Cooling Air Volume (Nm³/kgcli) | ~2.0 2.2 Nm³/kgcli| ≤1.8 Nm³/kgcli| Шалтгаална, хамаарна 10% бууруулах |
| Дулаан сэргээх үр ашиг (%)| ~70 72%| >74%| ~35% increase |
| Сараалжтай хавтангийн үйлчилгээний хугацаа (сар) | ~36 48 сар| >60 сар| ~25% longer lifespan |
| Цахилгаан эрчим хүчний хэрэглээ (kWh/tcli) | ~6 7 kWh/tcli| ~5 5.5 kWh/tcli| Шалтгаална, хамаарна 15% бууруулах |
| Клинкерийн гаралтын температур (°C) Ambient +80100°C| Ambient +65°C max.| More consistent grindability |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 2,500 нь 10,000 Өдөрт тонн (TPD) клинкер.
Эрчим хүчний шаардлага: Total connected load varies by size; жишээ нь e., аг 5,000 TPD cooler requires approximately 8001000 kW for all fans and drives (3үе шат, үйлдвэрийн техникийн үзүүлэлтийн дагуу хүчдэл).
Материалын үзүүлэлтүүд: Grate plates cast in ZCr26Ni12 highchromium alloy; side liners in abrasionresistant steel; housing constructed from carbon steel with internal refractory lining in hot zones.
Физик хэмжээсүүд (Example for 5k TPD): Overall length ~35m; өргөн ~ 6м; height from ground level ~10m.
Байгаль орчны үйл ажиллагааны хүрээ: 20°С-аас +50°С хүртэлх орчны температурт зориулагдсан; dustladen environment compatible.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

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 АРИЛЖААНЫ ХЭРЭГЛЭЭ

Тоног төхөөрөмжийн үнийг хүчин чадлаар нь ангилдаг(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 Түгээмэл асуултууд

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