H1: HighEfficiency Clinker Cooler Systems for Modern Cement Production

1. PAINPOINT DRIVE NOLEING

Managing the clinker cooling process is a critical bottleneck that directly impacts your plant’s bottom line. Inefficient cooling leads to substantial, quantifiable losses: excessive fuel consumption in the kiln due to poor heat recovery, reduced grinding mill efficiency from hot clinker, and unpredictable equipment downtime from thermal stress and mechanical failure. Are you contending with inconsistent clinker quality, high secondary air temperatures that damage ID fans, or escalating maintenance costs on grate plates and drives? These challenges are not merely operational headaches; they represent a direct erosion of profitability through wasted energy, lost production time, болон солих ажилд хугацаанаас нь өмнө хөрөнгийн зарцуулалт.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

Бидний reciprocating grate clinker cooler is engineered for maximum thermal efficiency and operational reliability in cement pyroprocessing. The system operates on a controlled, phased workflow: (1) Quenching of kiln discharge material (13001400°C) on the fixed grate for rapid temperature stabilization. (2) Controlled conveying and gradual cooling via reciprocating grates with forced air ventilation across multiple zones. (3) Efficient heat recuperation where secondary air is returned to the kiln and tertiary air to the calciner. (4) Final cooling to ambient temperatures suitable for conveying and storage. This solution is designed for integrated cement plant operations with kiln capacities from 2000 нь 10,000+ TPD. Its primary limitation is a requirement for consistent clinker granulometry; extreme variations can affect grate bed permeability and cooling uniformity.

3. ҮНДСЭН ОНЦЛОГ

Modular Grate Plate Design | Техникийн үндэслэл: Өндөр хром, nickelalloy castings with optimized venting geometry | Үйл ажиллагааны ашиг тус: Individual plate replacement reduces downtime by up to 70% compared to sectional repairs | ROI нөлөө: Lowers lifetime maintenance costs and sustains cooler availability above 98%.

Advanced Air Flow Management | Техникийн үндэслэл: Independently controlled fan zones with precision dampers and pressure monitoring | Үйл ажиллагааны ашиг тус: Achieves optimal heat recovery (>72% бүтээмж) and consistent clinker exit temperature below ambient +65°C | ROI нөлөө: Reduces specific heat consumption in the kiln by 2535 ккал/кг чулуунцар.

Robust Drive & Frame System | Техникийн үндэслэл: Hydraulic drive units with loadsensing technology and reinforced, thermally isolated support structure | Үйл ажиллагааны ашиг тус: Eliminates misalignment issues and maintains consistent grate stroke under varying load conditions | ROI нөлөө: Extends mechanical service life by an estimated 40%, deferring major drive system overhaul.

Integrated Redundancy & Дуусг m түвшин | Техникийн үндэслэл: Critical components (шүтэн бишрэгчид, Шумбах) in N+1 configuration with full SCADA integration for thermal imaging and pressure mapping | Үйл ажиллагааны ашиг тус: Allows for predictive maintenance scheduling and prevents unplanned stoppages | ROI нөлөө: Minimizes production loss risk from cooler subsystem failure.

HighEfficiency Heat Recovery Ducting | Техникийн үндэслэл: Тооцооллын шингэний динамик (Хөжиг)optimized duct design with ceramic refractory lining | Үйл ажиллагааны ашиг тус: Maximizes volume & temperature of secondary/tertiary air returned to combustion processes | ROI нөлөө: Directly lowers fossil fuel requirements, improving overall plant energy economics.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт жишиг | Our Clinker Cooler Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Cooling Efficiency | ~70% Thermal Recovery | >72% Thermal Recovery | +23% Оноо |
| Клинкерээс гарах температур| Ambient +80°C to +100°C| Ambient +65°C or lower| ~25%-ийн бууралт |
| Specific Air Consumption| 2.0 2.2 Nm³/kg clinker| 1.8 1.9 Nm³/kg clinker| ~10% бууруулах |
| Сараалжтай хавтангийн үйлчилгээний хугацаа| 1218 сарын дундаж| 2430 months demonstrated| ~67% өснө |
| Үйл ажиллагааны хүртээмж| 9496% typical availability|<98% баримтжуулсан бэлэн байдал|<4% Харьцангуй сайжруулалт |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: Configurable for kiln outputs from 2,000 нь 12,000 Өдөрт тонн (TPD).
Эрчим хүчний шаардлага: Total installed fan power varies by size; жишээ нь e., аг 5,000 TPD нэгж ойролцоогоор шаардлагатай 8001000 kw.
Материалын үзүүлэлтүүд: Grate plates cast from GX40CrNiSi275 alloy; side liners in Mn steel; housing in carbon steel with internal refractory.
Физик хэмжээсүүд: Загвараас хамаарч өөр өөр байдаг; a standard unit for a 5,500 TPD line is approximately L=45m x W=12m x H=10m.
Байгаль орчны үйл ажиллагааны хүрээ: 20°С-аас +50°С хүртэлх орчны температурт зориулагдсан; dusttight housing maintains performance in all weather conditions.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Plant Capacity Upgrade Challenge Challenge: A Southeast Asian plant upgrading kiln capacity faced a bottleneck—their existing cooler could not handle increased throughput or provide stable tertiary air temperature.Шийдлийн хэрэгжилт: A customwidth reciprocating grate cooler was installed with enhanced air distribution zones.Results Quantifiable Outcomes: Achieved full design capacity of 6,500 TPD with tertiary air temperature stabilized at >950°C, contributing to a total kiln system fuel saving of 4%.