1. ABERTURA ACIONADA POR PAINPOINT

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. VISÃO GERAL DO PRODUTO

O 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: Hot clinker (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. Recuperação de calor: 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 & Descarga: Reciprocating grates convey the cooled clinker (below 100°C + ambient) 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).

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

3. RECURSOS PRINCIPAIS

Advanced Grate Plate Design | Base Técnica: Highresistance cast alloy with optimized orifice geometry | Benefício Operacional: Ensures uniform air distribution across the entire bed, preventing "rio vermelho" phenomena and hot spots | Impacto do ROI: Reduces refractory wear costs by up to 30% and improves heat recovery consistency

Modular Drive System | Base Técnica: Independent hydraulic drives per grate module | Benefício Operacional: Allows precise control of grate speed and stroke length for different cooling zones, adapting to variable kiln output | Impacto do ROI: Increases throughput flexibility and optimizes specific cooling air volume, lowering fan power consumption

HighEfficiency Fans & Ducting | Base Técnica: Aerodynamically optimized fans with variable frequency drives (Inversores de frequência) and insulated ductwork | Benefício Operacional: Delivers exact air volume per zone with minimal pressure loss, maximizing secondary/tertiary air temperature | Impacto do ROI: Os dados de campo mostram um 25% reduction in specific heat consumption through improved thermal recuperation

Robust Casing & Sealing System | Base Técnica: Heavyduty steel construction with labyrinth seals and compensated expansion joints | Benefício Operacional: Maintains negative pressure operation, eliminating dust emission points and false air ingress | Impacto do ROI: Lowers environmental compliance risk and improves overall system fan efficiency

Integrated Process Control Logic | Base Técnica: PLCbased system linked to kiln feed, drive speeds, and fan VFDs | Benefício Operacional: Your operators benefit from automated response to process upsets, maintaining optimal bed depth and airtoclinker ratios | Impacto do ROI: Stabilizes kiln operation, reduces operator intervention, and protects equipment from thermal shock

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Industry Standard Grate Cooler | Advanced Grate Clinker Cooler Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Clinker Discharge Temperature | 100°C + Ambiente | 7275% of input heat recovered| +58 pontos percentuais |
| Specific Cooling Air Volume (Nm³/kgclinker)~2.0 2.4 Nm³/kgcli| ~1,8 2.0 Nm³/kgcli under optimal control| Reduction of ~1015% |
| Vida útil da placa de grelha (Refractory Lined)| 1218 months average| 2430 months demonstrated life| +50100% melhoria |
| Operating Availability (excluindo paradas planejadas)| ~9092% typical availability target| >95% availability achievable through design redundancy|<5 aumento de pontos percentuais |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 1,500 acabar 12,000 toneladas por dia (TPD) de clínquer.
Requisitos de energia: 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.
Especificações de materiais:
Grate Plates & Forros laterais: Highchrome cast iron alloys (2530% Cr).
Casing & Ducting: Carbon steel plate with internal refractory lining in hightemperature zones.
Fan Impellers & Habitação: Construção em chapa de aço resistente à abrasão.
Dimensões Físicas: Varies significantly by capacity; a unit for a 5,000 TPD plant typically requires a footprint of approximately ~25m (eu) x ~8m (C), excluding ductwork.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; electrical components rated per local standards (por exemplo, IEC/IP ratings).

6. CENÁRIOS DE APLICAÇÃO

Plant Capacity Expansion Retrofit

Desafio: 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.
Solução: Installation of a new modular Grate Clinker Cooler designed for higher throughput but within existing structural footprint constraints.
Resultados: 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

Desafio:A European plant increasing its use of alternative fuels experienced greater variability in clinker porosity and temperature profile at the kiln hood.
Solução:A Grate Clinker Cooler featuring advanced zonal control logic was implemented alongside new highpressure fan modules.
Resultados: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. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Capital cost varies based on capacity:
Nível I (7k TPD): Fully bespoke designs including integrated process optimization packages.

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

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

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

8.Perguntas frequentes

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