1. PAINPOINT DRIVEN OPENING

Are you facing persistent bottlenecks in your cement production line that erode profitability? For plant managers and engineering contractors, the clinker cooler is a critical yet problematic node. Common operational challenges include:
Excessive Heat Recuperation Loss: Inefficient cooling wastes thermal energy, increasing specific heat consumption by 1525 kcal/kgclinker and directly raising fuel costs.
High Clinker Outlet Temperature: Residual temperatures exceeding 100°C+ ambient strain downstream equipment like conveyor belts and elevators, accelerating wear and increasing maintenance frequency.
Inconsistent Cooling & Quality Degradation: Uneven air distribution creates "hot spots," leading to poor quenching that reduces cement strength (lower C3S formation) and can cause false set.
High Maintenance Downtime: Frequent refractory damage, grate plate failures, and highpressure fan issues lead to unplanned shutdowns, costing thousands per hour in lost production.
Elevated Environmental Footprint: Poor combustion of recycled air results in higher secondary air temperatures at the kiln inlet and potential issues with NOx formation.

Is your current cooler system a source of variable cost and operational uncertainty? The solution lies not in offtheshelf machinery, but in precisionengineered customization.

2. PRODUCT OVERVIEW: ODM Grate Cooler for Cement Clinker

This product is a fully customized, heavyduty reciprocating grate cooler engineered for the efficient cooling of cement clinker from rotary kiln discharge temperatures (~1400°C) to a handling temperature below 100°C + ambient.

Operational Workflow:
1. Clinker Distribution: Hot clinker from the kiln is evenly distributed across the full width of the static inlet grate via an adjustable weir plate.
2. Reciprocating Cooling: Hydraulically driven grate rows move reciprocally to transport clinker through multiple cooling zones (typically hot, intermediate, and final). Controlled undergrate compartmentalized fans supply cooling air.
3. Heat Recuperation: Hightemperature secondary air (8001200°C) is efficiently recovered at the kiln hood and directed back to the rotary kiln as combustion air.
4. Efficient Quenching & Transport: As clinker moves, it is progressively cooled by forced air convection. Fully cooled clinker is discharged to the crusher and subsequent conveying system.

Application Scope & Limitations:
Scope: Designed for integration into new dryprocess cement production lines or as a retrofit replacement for inefficient planetary or older grate coolers in plants with capacities from 1000 to 12,000 TPD.
Limitations: Performance is contingent on proper integration with kiln feed chemistry, consistent kiln operation, and adherence to prescribed maintenance schedules. Not suitable for wetprocess plants or alternative fuel operations without specific design adaptations.

3. CORE FEATURES

Modular Grate Plate System | Technical Basis: Highchrome alloy casting with optimized venting design | Operational Benefit: Exceptional resistance to thermal shock and abrasion; individual plates can be replaced without stopping the entire cooler | ROI Impact: Reduces refractory replacement downtime by up to 60% and extends campaign life.

Compartmentalized Air Control | Technical Basis: Independently controlled highpressure fan units per sealed compartment with automatic damper regulation | Operational Benefit: Precise air distribution across the clinker bed depth eliminates hot spots and optimizes heat recovery | ROI Impact: Improves secondary air temperature consistency by ±15°C, boosting kiln burning zone stability and reducing specific heat consumption.

Hydraulic Drive System with Frequency Control | Technical Basis: Redundant hydraulic power units driving grate rows with variable speed control | Operational Benefit: Smooth, adjustable clinker transport speed allows finetuning for varying kiln throughputs; high reliability with online backup | ROI Impact: Minimizes mechanical shock loads, reducing drive system maintenance costs by an estimated 30% yearoveryear.

Advanced Heat Recuperation Design | Technical Basis: Optimized hood geometry and tight sealing around moving grates | Operational Benefit: Maximizes recovery of highenthalpy secondary air while minimizing false air infiltration | ROI Impact: Field data shows a consistent reduction of 2030 kcal/kgclinker in heat consumption versus outdated designs.

Integrated Process Control Interface | Technical Basis: PLCbased system with standard communication protocols (Profibus, Modbus) | Operational Benefit: Provides operators with realtime data on pressure gradients, temperatures, and drive status for proactive management | ROI Impact: Enables predictive maintenance scheduling and rapid fault diagnosis, preventing costly escalation of minor issues.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Older Grate Designs) | ODM Grate Cooler Solution | Advantage (% Improvement) |
| : | : | : | : |
| Clinker Outlet Temperature
(Above Ambient) | ~120 150°C | < 100°C + Ambient| ~25% Reduction |
| Heat Recuperation Efficiency
(Secondary Air Temp.)| Often inconsistent; averages lower target temp.| Consistent delivery at >1050°C target| Up to 10% more thermal energy returned |
| Specific Cooling Air Volume
(Nm³/kgclinker) | ~2.0 2.5 Nm³/kgclinker| Optimized to ~1.8 2.2 Nm³/kgclinker| Up to 15% reduction in fan power consumption |
| Grate Plate Service Life
(Under Normal Conditions)| ~1218 months| >24 months typical service life| ~50% increase in mean time between replacements|
| Operational Availability
(After first year)| ~9294% availability common|<96% availability achievable through robust design & redundancy|<5% relative improvement in uptime|

5. TECHNICAL SPECIFICATIONS

Capacity Range (Customizable): From 1,000 to over 10,000 Tons Per Day (TPD) of clinker.
Power Requirements: Dependent on size; primary consumers are compartmentalized highpressure fans (total installed power range: 200 kW – 1500 kW) and hydraulic drive units (50 kW – 300 kW). Voltage as per plant specification (e.g., 380V/415V/6.6kV).
Material Specifications:
Grate Plates & Side Liners: HighChrome Alloy Castings (Cr content >25%).
Hood & Casing: Carbon steel plate with internal refractory lining in highheat zones.
Grate Frame Structure: Heavyduty welded carbon steel sections.
Physical Dimensions (Example for ~5000 TPD): Approx. Length: 35m; Width: 6m; Height at hood peak: ~8m. Fully customized per layout.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dustladen environment standard.

6. APPLICATION SCENARIOS

Plant Capacity Upgrade Retrofit

Challenge A midsized plant upgrading kiln capacity from 3200 TPD to 4200 TPD was constrained by an existing cooler causing high outlet temperatures (>130°C) and frequent stoppages.
Solution A fully customized ODM grate cooler was designed for the new capacity within the existing building footprint constraints using a wider but shorter layout with enhanced fan configuration.
Results Clinker outlet temperature stabilized below <95°C+ ambient within six months of commissioning; coolerrelated downtime decreased by over twothirds; total upgrade project achieved payback within two years due to increased throughput stability.

Alternative Fuel Utilization Project

Challenge A plant increasing its use of alternative fuels experienced higher variability in clinker granulometry and temperature at the kiln hoods impacting traditional cooler efficiency
Solution The ODM solution incorporated a reinforced static inlet section ("grizzly") for coarse fragment handling adjusted compartmental airflow logic specifically tuned for greater input variability
Results The customized system maintained consistent bed permeability achieving target secondary air temperatures despite variable feed conditions enabling a successful increase alternative fuel thermal substitution rate from

Energy Efficiency Overhaul

Challenge Facing rising energy costs an older plant identified its outdated planetary cooler as major source inefficiency poor heat recovery contributing excessive specific heat consumption
Solution Replacement with modern ODM grate cooler featuring advanced sealing compartmentalization optimized recuperation ductwork
Results Postinstallation thermal analysis confirmed reduction specific heat consumption kcal kgclinken annual fuel cost savings exceeded million dollars project justification

COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are projectspecific based on capacity customization level material selections

Base Configuration Includes core structure standard grate plates basic hydraulic drive compartment fans essential instrumentation Optional features upgrades include:
Advanced alloy grades extended service life
Redundant hydraulic power units missioncritical applications
Full instrumentation package including thermal imaging bed depth scanners
Specialized refractories extreme operating conditions

Service Packages Available:
Extended warranty coverage critical components years)
Annual inspection maintenance contracts spare parts provisioning
Remote monitoring diagnostics subscription

Financing Options We work financial partners offer solutions including equipment leasing longterm payment plans facilitating capital expenditure approvals

FAQ

What key data required provide preliminary ODM quotation?
We require current intended clinkern production rate TPD chemical analysis typical granulometry available plot plan footprint existing ancillary equipment specifications fans dust collectors)

How does new cooler integrate our existing DCS control system?
Our PLCbased control panel designed interface seamlessly via standard industrial communication protocols Profibus Modbus TCP/IP We provide necessary drivers documentation smooth integration your plant DCS

What typical installation timeline disruption production?
For greenfield projects delivery follows overall construction schedule For brownfield retrofits we develop detailed phased execution plan minimize downtime typically involving prefabricated modules Critical path outage typically weeks depending complexity Existing foundation reuse possible reducing civil work time

Can upgraded handle different types fuels?
Yes customization process specifically addresses operational parameters associated alternative fuels refuse derived fuel tires etc This includes material selections airflow management strategies ensure performance longevity under varied conditions

What aftersales support provided?
Support includes comprehensive commissioning supervision by our engineers operator training manuals access technical documentation Ongoing support available through dedicated service team remote troubleshooting assistance guaranteed spare parts supply chain

Are performance guarantees offered?
Yes we provide contractual guarantees regarding key performance indicators KPIs including guaranteed maximum clinkern outlet temperature minimum secondary air temperature specific cooling air consumption subject defined baseline operating conditions