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 energy recovery for your preheater and calciner systems. Uncontrolled quenching can result in poor cement quality and increased wear on downstream equipment like crushers and conveyors. Frequent maintenance stops for refractory repair or grate replacement cause unplanned downtime, directly impacting your production tonnage and bottom line.

Are you facing high secondary air temperatures, inconsistent clinker bed permeability, or rising specific power consumption at your mill? Is your current cooler struggling with varying feed rates or producing clinker with residual heat that stresses material handling systems? The solution requires a system engineered not just to cool, but to optimize the entire thermal and mechanical chain.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

Тухайлах ялгац гишүүн Grate Clinker Cooler is a reciprocating, airpermeable bed system designed for efficient heat recovery and quenching of cement clinker exiting the rotary kiln. Its operational workflow is defined by controlled, staged cooling:

1. Controlled Infeed: Халуун клинкер (approximately 12001400°C) from the kiln is evenly distributed across the cooler grate.
2. Staged Air Quenching: Highpressure cooling fans force ambient air upward through the moving grate and clinker bed in multiple zones, enabling precise temperature control.
3. Дулаан сэргээх: The heated secondary air is directed back to the kiln combustion zone, while tertiary air is supplied to the calciner, significantly improving kiln system fuel efficiency.
4. Clinker Transport & Ахах: Reciprocating grates convey the cooled clinker (below 100°C + орчин) to the discharge end for transfer to the cement mill.
5. Fines Handling: A dusttight casing and integrated drag chain conveyor manage cooler fines (grate spill).

Хэрэглээний хамрах хүрээ: Ideal for medium to largecapacity dryprocess cement plants with rotary kilns. Хувьсгал: Performance is highly dependent on consistent clinker granulometry; not suitable for wet process plants or very lowcapacity operations without significant design modification.

3. ҮНДСЭН ОНЦЛОГ

Advanced Grate Plate Design | Техникийн үндэслэл: Highresistance cast alloy with optimized orifice geometry | Үйл ажиллагааны ашиг тус: Ensures uniform air distribution across the entire bed, preventing "улаан гол" phenomena and hot spots | ROI нөлөө: Reduces refractory wear costs by up to 30% and improves heat recovery consistency

Modular Drive System | Техникийн үндэслэл: Independent hydraulic drives per grate module | Үйл ажиллагааны ашиг тус: Allows precise control of grate speed and stroke length for different cooling zones, adapting to variable kiln output | ROI нөлөө: Increases throughput flexibility and optimizes specific cooling air volume, lowering fan power consumption

HighEfficiency Fans & Ducting | Техникийн үндэслэл: Aerodynamically optimized fans with variable frequency drives (Vfds) and insulated ductwork | Үйл ажиллагааны ашиг тус: Delivers exact air volume per zone with minimal pressure loss, maximizing secondary/tertiary air temperature | ROI нөлөө: Талбайн өгөгдөл нь a 25% reduction in specific heat consumption through improved thermal recuperation

Robust Casing & Sealing System | Техникийн үндэслэл: Heavyduty steel construction with labyrinth seals and compensated expansion joints | Үйл ажиллагааны ашиг тус: Maintains negative pressure operation, eliminating dust emission points and false air ingress | ROI нөлөө: Lowers environmental compliance risk and improves overall system fan efficiency

Integrated Process Control Logic | Техникийн үндэслэл: PLCbased system linked to kiln feed, drive speeds, and fan VFDs | Үйл ажиллагааны ашиг тус: Your operators benefit from automated response to process upsets, maintaining optimal bed depth and airtoclinker ratios | ROI нөлөө: Stabilizes kiln operation, reduces operator intervention, and protects equipment from thermal shock

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт сараалжтай хөргөгч | Advanced Grate Clinker Cooler Solution | Давуу тал (% сайжруулалт) |
| : | : | : | : |
| Clinker Discharge Temperature | 100°C + Хүрээлэн буй орчин | 7275% of input heat recovered| +58 хувь оноо |
| Specific Cooling Air Volume (Nm³/kgclinker)~2.0 2.4 Nm³/kgcli| ~1.8 2.0 Nm³/kgcli under optimal control| Reduction of ~1015% |
| Сараалжтай хавтангийн үйлчилгээний хугацаа (Refractory Lined)| 1218 months average| 2430 сар амьдралыг харуулсан| +50100% сайжруулалт |
| Operating Availability (төлөвлөсөн зогсоолоос бусад)| ~9092% typical availability target| >95% availability achievable through design redundancy|<5 нэгж хувиар өссөн байна |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 1,500 дээр нь 12,000 тонн тонн (TPD) клинкер.
Эрчим хүчний шаардлага: Total installed fan power ranges from ~500 kW for a 2,500 TPD unit to over 2,500 kW for large installations; all major drives utilize VFDs.
Материалын үзүүлэлтүүд:
Grate Plates & Хажуугийн доторлогоо: Highchrome cast iron alloys (2530% Cr).
Casing & Ducting: Carbon steel plate with internal refractory lining in hightemperature zones.
Fan Impellers & Орон сууц: Abrasionresistant steel plate construction.
Физик хэмжээсүүд: Varies significantly by capacity; a unit for a 5,000 TPD plant typically requires a footprint of approximately ~25m (Дээд) x ~8m (Үнэр), excluding ductwork.
Байгаль орчны үйл ажиллагааны хүрээ: 20°С-аас +45°С хүртэлх орчны температурт зориулагдсан; electrical components rated per local standards (жишээ нь e., IEC/IP ratings).

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Plant Capacity Expansion Retrofit

Сорилт: A North American plant upgrading kiln capacity by 20% found its existing cooler was the limiting factor, causing high discharge temperatures that damaged the pan conveyor.
Хариу: Installation of a new modular Grate Clinker Cooler designed for higher throughput but within existing structural footprint constraints.
Үр дүн: Achieved full design capacity increase while reducing final clinker temperature by an average of 25°C; specific power consumption at the cement mill decreased due to cooler feed material.

Fuel Flexibility & Alternative Fuel Usage

Сорилт:A European plant increasing its use of alternative fuels experienced greater variability in clinker porosity and temperature profile at the kiln hood.
Хариу:A Grate Clinker Cooler featuring advanced zonal control logic was implemented alongside new highpressure fan modules.
Үр дүн:The enhanced control stabilized secondary air temperature fluctuations by ±15°C despite variable feed conditions; this improved overall kiln combustion stability when using heterogeneous fuels.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Үнийн шатлал: Capital cost varies based on capacity:
I шат (7к TPD): Fully bespoke designs including integrated process optimization packages.

Нэмэлт шинж чанарууд: Upgrades include advanced condition monitoring sensors on grates/bearings; hot gas bypass systems; premiumgrade refractory packages; fullscale digital twin integration.

Үйлчилгээний багцууд: Multiyear service agreements are available covering scheduled inspections predictive maintenance based on vibration/temperature analysis spare parts provisioning at guaranteed rates.

Санхүүжилтийн сонголтууд: Project financing can be structured through partner institutions including leasetoown models or performancelinked repayment schedules where savings guarantee payments.

8.Түгээмэл асуултууд

Q1.Is this equipment compatible with our existing rotary kiln discharge housing?
A.Engineering assessments are required but standard interface designs allow adaptation most modern suspensiontype hoods detailed dimensional survey ensures fitment.

Q2.What impact will installation have on our current production schedule?
A.A wellplanned retrofit typically involves staged execution during scheduled major maintenance shutdown minimizing total downtime impact detailed critical path plan provided early project phases.

Q3.How does this solution improve our return on investment beyond just equipment cost?
A.Primary ROI drivers are reduced specific fuel consumption via higher heat recovery lower electrical consumption via optimized fans reduced maintenance costs extended component life quantifiable savings model developed during proposal stage.

Q4.What are standard commercial terms regarding payment delivery warranty?
A.Typical terms involve progress payments tied milestones FOB shipping point delivery warranties cover materials workmanship core components years extended warranties available service agreement activation.

Q5.Do you provide supervision commissioning operator training?
A.Comprehensive implementation support includes resident site engineers during erection cold hot commissioning phases structured classroom field training programs your operational technical staff included scope supply