1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Bạn đang phải đối mặt với những tắc nghẽn dai dẳng trong dây chuyền sản xuất xi măng làm giảm lợi nhuận? Dành cho người quản lý nhà máy và nhà thầu kỹ thuật, the clinker cooler is a critical yet problematic node. Những thách thức hoạt động chung bao gồm:
Mất thu hồi nhiệt quá mức: 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.
Thời gian ngừng bảo trì cao: Frequent refractory damage, grate plate failures, and highpressure fan issues lead to unplanned shutdowns, gây thiệt hại hàng ngàn mỗi giờ trong sản xuất bị mất.
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? Giải pháp không nằm ở máy móc có sẵn, nhưng trong sự tùy chỉnh được thiết kế chính xác.

2. TỔNG QUAN SẢN PHẨM: 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 + môi trường xung quanh.

Quy trình hoạt động:
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 & Chuyên chở: As clinker moves, it is progressively cooled by forced air convection. Fully cooled clinker is discharged to the crusher and subsequent conveying system.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: 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 ĐẾN 12,000 TPD.
Hạn chế: 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. TÍNH NĂNG CỐT LÕI

Hệ thống tấm lưới mô-đun | Cơ sở kỹ thuật: Highchrome alloy casting with optimized venting design | Lợi ích hoạt động: Khả năng chống sốc nhiệt và mài mòn đặc biệt; individual plates can be replaced without stopping the entire cooler | Tác động ROI: Giảm thời gian ngừng hoạt động thay thế vật liệu chịu lửa lên tới 60% and extends campaign life.

Compartmentalized Air Control | Cơ sở kỹ thuật: Independently controlled highpressure fan units per sealed compartment with automatic damper regulation | Lợi ích hoạt động: Precise air distribution across the clinker bed depth eliminates hot spots and optimizes heat recovery | Tác động ROI: Improves secondary air temperature consistency by ±15°C, boosting kiln burning zone stability and reducing specific heat consumption.

Hệ thống truyền động thủy lực có điều khiển tần số | Cơ sở kỹ thuật: Redundant hydraulic power units driving grate rows with variable speed control | Lợi ích hoạt động: Trơn tru, adjustable clinker transport speed allows finetuning for varying kiln throughputs; high reliability with online backup | Tác động ROI: Minimizes mechanical shock loads, reducing drive system maintenance costs by an estimated 30% năm này qua năm khác.

Advanced Heat Recuperation Design | Cơ sở kỹ thuật: Optimized hood geometry and tight sealing around moving grates | Lợi ích hoạt động: Maximizes recovery of highenthalpy secondary air while minimizing false air infiltration | Tác động ROI: Field data shows a consistent reduction of 2030 kcal/kgclinker in heat consumption versus outdated designs.

Giao diện điều khiển quy trình tích hợp | Cơ sở kỹ thuật: PLCbased system with standard communication protocols (Hồ sơ, Modbus) | Lợi ích hoạt động: Provides operators with realtime data on pressure gradients, nhiệt độ, and drive status for proactive management | Tác động ROI: Enables predictive maintenance scheduling and rapid fault diagnosis, preventing costly escalation of minor issues.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Older Grate Designs) | ODM Grate Cooler Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Nhiệt độ đầu ra clinker
(Above Ambient) | ~120 150°C | < 100°C + Môi trường xung quanh| ~ Giảm 25% |
| Hiệu quả thu hồi nhiệt
(Nhiệt độ không khí thứ cấp.)| Often inconsistent; averages lower target temp.| Consistent delivery at >1050°C target| Lên đến 10% more thermal energy returned |
| Khối lượng không khí làm mát cụ thể
(Nm³/kgclinker) | ~2.0 2.5 Nm³/kgclinker| Optimized to ~1.8 2.2 Nm³/kgclinker| Lên đến 15% reduction in fan power consumption |
| Tuổi thọ của tấm lưới
(Under Normal Conditions)| ~1218 tháng| >24 months typical service life| ~50% increase in mean time between replacements|
| Sẵn sàng hoạt động
(After first year)| ~9294% availability common|<96% availability achievable through robust design & sự dư thừa|<5% relative improvement in uptime|

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất (Customizable): Từ 1,000 đến hơn 10,000 Tấn mỗi ngày (TPD) của clanhke.
Yêu cầu về nguồn điện: Phụ thuộc vào kích thước; 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 (ví dụ., 380V/415V/6.6kV).
Thông số vật liệu:
tấm lưới & Side Liners: HighChrome Alloy Castings (Cr content >25%).
Hood & Vỏ bọc: Carbon steel plate with internal refractory lining in highheat zones.
Grate Frame Structure: Heavyduty welded carbon steel sections.
Kích thước vật lý (Example for ~5000 TPD): Xấp xỉ. Chiều dài: 35tôi; Chiều rộng: 6tôi; Height at hood peak: ~8m. Fully customized per layout.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +50°C; dustladen environment standard.

6. KỊCH BẢN ỨNG DỤNG

Plant Capacity Upgrade Retrofit

Challenge A midsized plant upgrading kiln capacity from 3200 TPD sang 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 ("hoa râm") 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

CÂN NHẮC THƯƠNG MẠI

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

Gói dịch vụ có sẵn:
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

Câu hỏi thường gặp

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

Có đảm bảo hiệu suất được cung cấp?
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