H1: HighEfficiency Clinker Cooler Systems for Modern Cement Production

1. PEMBUKAAN PAINPOINT DRIVEN

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, dan perbelanjaan modal pramatang untuk penggantian.

2. GAMBARAN KESELURUHAN PRODUK

Kami 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 ke 10,000+ TPD. Its primary limitation is a requirement for consistent clinker granulometry; extreme variations can affect grate bed permeability and cooling uniformity.

3. CIRI TERAS

Modular Grate Plate Design | Asas Teknikal: Highchromium, nickelalloy castings with optimized venting geometry | Faedah Operasi: Individual plate replacement reduces downtime by up to 70% compared to sectional repairs | Kesan ROI: Lowers lifetime maintenance costs and sustains cooler availability above 98%.

Advanced Air Flow Management | Asas Teknikal: Independently controlled fan zones with precision dampers and pressure monitoring | Faedah Operasi: Achieves optimal heat recovery (>72% kecekapan) and consistent clinker exit temperature below ambient +65°C | Kesan ROI: Reduces specific heat consumption in the kiln by 2535 kcal/kg klinker.

Pemacu Teguh & Frame System | Asas Teknikal: Hydraulic drive units with loadsensing technology and reinforced, thermally isolated support structure | Faedah Operasi: Eliminates misalignment issues and maintains consistent grate stroke under varying load conditions | Kesan ROI: Extends mechanical service life by an estimated 40%, deferring major drive system overhaul.

Integrated Redundancy & Pemantauan | Asas Teknikal: Critical components (peminat, PLCS) in N+1 configuration with full SCADA integration for thermal imaging and pressure mapping | Faedah Operasi: Allows for predictive maintenance scheduling and prevents unplanned stoppages | Kesan ROI: Minimizes production loss risk from cooler subsystem failure.

HighEfficiency Heat Recovery Ducting | Asas Teknikal: Dinamik Bendalir Pengiraan (Cfd)optimized duct design with ceramic refractory lining | Faedah Operasi: Maximizes volume & temperature of secondary/tertiary air returned to combustion processes | Kesan ROI: Directly lowers fossil fuel requirements, improving overall plant energy economics.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Our Clinker Cooler Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Cooling Efficiency | ~70% Thermal Recovery | >72% Pemulihan Terma | +23% Points |
| Suhu Keluar Klinker| Ambient +80°C to +100°C| Ambient +65°C or lower| ~25% Pengurangan |
| Specific Air Consumption| 2.0 2.2 Nm³/kg clinker| 1.8 1.9 Nm³/kg clinker| ~10% Reduction |
| Hayat Perkhidmatan Plat Parut| 1218 months average| 2430 months demonstrated| ~67% Peningkatan |
| Operating Availability| 9496% typical availability|<98% ketersediaan yang didokumenkan|<4% Penambahbaikan Relatif |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Configurable for kiln outputs from 2,000 ke 12,000 Tan Sehari (TPD).
Keperluan kuasa: Total installed fan power varies by size; mis., a 5,000 TPD unit requires approximately 8001000 kw.
Spesifikasi Bahan: Grate plates cast from GX40CrNiSi275 alloy; side liners in Mn steel; housing in carbon steel with internal refractory.
Dimensi Fizikal: Berbeza mengikut model; a standard unit for a 5,500 TPD line is approximately L=45m x W=12m x H=10m.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C; perumahan kedap debu mengekalkan prestasi dalam semua keadaan cuaca.

6. SENARIO APLIKASI

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.Pelaksanaan Penyelesaian: 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%.