Custom Cement Plant Equipment Vendor
ايڇ 1: HighEfficiency Clinker Cooler Systems for Modern Cement Production
1. PAINPOINT driven اوپننگ
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, and premature capital expenditure on replacements.
2. پيداوار جو جائزو
اسان جي 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 جي طرف 10,000+ ٽي پي ڊي. Its primary limitation is a requirement for consistent clinker granulometry; extreme variations can affect grate bed permeability and cooling uniformity.
3. بنيادي خاصيتون
Modular Grate Plate Design | ٽيڪنيڪل بنياد: Highchromium, nickelalloy castings with optimized venting geometry | آپريشنل فائدا: Individual plate replacement reduces downtime by up to 70% compared to sectional repairs | ROI اثر: Lowers lifetime maintenance costs and sustains cooler availability above 98%.
Advanced Air Flow Management | ٽيڪنيڪل بنياد: Independently controlled fan zones with precision dampers and pressure monitoring | آپريشنل فائدا: Achieves optimal heat recovery (>72% ڪارڪردگي) and consistent clinker exit temperature below ambient +65°C | ROI اثر: Reduces specific heat consumption in the kiln by 2535 kcal/kg ڪلينر.
Robust Drive & Frame System | ٽيڪنيڪل بنياد: Hydraulic drive units with loadsensing technology and reinforced, thermally isolated support structure | آپريشنل فائدا: Eliminates misalignment issues and maintains consistent grate stroke under varying load conditions | ROI اثر: Extends mechanical service life by an estimated 40%, deferring major drive system overhaul.
Integrated Redundancy & نگراني | ٽيڪنيڪل بنياد: Critical components (مداح, PLCs) in N+1 configuration with full SCADA integration for thermal imaging and pressure mapping | آپريشنل فائدا: Allows for predictive maintenance scheduling and prevents unplanned stoppages | ROI اثر: Minimizes production loss risk from cooler subsystem failure.
HighEfficiency Heat Recovery Ducting | ٽيڪنيڪل بنياد: Computational Fluid Dynamics (سي ايف ڊي)optimized duct design with ceramic refractory lining | آپريشنل فائدا: Maximizes volume & temperature of secondary/tertiary air returned to combustion processes | ROI اثر: Directly lowers fossil fuel requirements, improving overall plant energy economics.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | Our Clinker Cooler Solution | فائدو (% سڌارو) |
| : | : | : | : |
| Cooling Efficiency | ~70% Thermal Recovery | >72% Thermal Recovery | +23% پوائنٽون |
| Clinker Exit Temperature| Ambient +80°C to +100°C| Ambient +65°C or lower| ~ 25٪ گهٽتائي |
| Specific Air Consumption| 2.0 2.2 Nm³/kg clinker| 1.8 1.9 Nm³/kg clinker| ~10% Reduction |
| گريٽ پليٽ سروس جي زندگي| 1218 مھينا اوسط| 2430 months demonstrated| ~ 67% واڌارو |
| آپريٽنگ دستيابي| 9496% typical availability|<98% دستاويزي دستيابي|<4% Relative Improvement |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: Configurable for kiln outputs from 2,000 جي طرف 12,000 ٽين في ڏينهن (ٽي پي ڊي).
بجلي جي گهرج: Total installed fan power varies by size; مثال, هڪ 5,000 TPD يونٽ لڳ ڀڳ جي ضرورت آهي 8001000 ڪلواٽ.
مواد جي وضاحت: Grate plates cast from GX40CrNiSi275 alloy; side liners in Mn steel; housing in carbon steel with internal refractory.
جسماني طول و عرض: ماڊل جي لحاظ کان مختلف آهي; a standard unit for a 5,500 TPD line is approximately L=45m x W=12m x H=10m.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل; dusttight housing maintains performance in all weather conditions.
6. درخواست جا منظر
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.حل لاڳو ڪرڻ: 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%.
