Post on 31-Jan-2018
A Langley Holdings Company Claudius Peters Projects GmbH
Clinker Cooling -Making the most out of your energy
VDMA May 2013
Stephan OehmeDirector Sales and Technology
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
Claudius Peters(China) Ltd.
Beijing
The Claudius Peters Group
Claudius Peters Technologies S.A.S.
Claudius Peters ProjectsGmbH
Claudius Peters AmericasInc.
Claudius Peters(UK) Ltd.
Claudius Peters(Italiana) srl.
Claudius Peters(Ibérica) S.A.
Claudius Peters(China) Ltd.Hong Kong
Claudius Petersdo Brasil Ltda.
Claudius Peters(Románia) SRL
Claudius Peters(India) Pvt. Ltd.
Claudius Peters(Asia Pacific) PTE. LTD.
A Langley Holdings Company Claudius Peters Projects GmbH
Cement production flow chart
Raw material stacker/reclaimer conveying
Raw material grinding
Blending siloPrecalcining
Rotary kiln Clinker cooler
Coal storage grinding & firing
Clinker storage
Cement grinding
Cement storage Packing palletising
truck loading
Pneumatic Conveying
Mixing
A Langley Holdings Company Claudius Peters Projects GmbH
112
Successful figures worldwide…
Claudius Peters – Experts in Clinker Cooling
coolers since 1950
CoolerConversions
HE-Module installationssince 1994
…for more than 60 Years
228
735
A Langley Holdings Company Claudius Peters Projects GmbH
CP Clinker Cooler Evolution
Claudius Peters Originator
► Hydraulic Drive 1976
► Roller Crusher 1978
► 10.000 tpd Cooler 1992
► Compact Swing Support 1998
► ETA Cooler 2004
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
High Efficiency Module (Static Inlet)
Protection
�Static layer protects the grate plates of the HE Module
A Langley Holdings Company Claudius Peters Projects GmbH
Principle of Movement
Movement pattern example with 4 lanes
Worldwide patents applied / pending
Forward stroke Step 1
Backwardsequence
1 2 3 4
Step 2
Step 3
Step 4
1 2 3 4
A Langley Holdings Company Claudius Peters Projects GmbH
93 % protected by simple stonesremaining ribs hardfaced
Self-Protective Design against Wear and Heat
Clinker bed
Wear protection
Hardfacing
A Langley Holdings Company Claudius Peters Projects GmbH
Holcim Siggenthal after 7 years of Operation
Only paint is off the cooler is ready for production
A Langley Holdings Company Claudius Peters Projects GmbH
Self Protection Summary
1: HE-Module:
HEM-Plates are protected by a static clinker layer
2: Aerated Lanes:
93% of the surface is covered with simple stones
• protection against mechanical wear
• protection against heat damage
3: Stroke length / Cycles:
Long stroke length causes slow movement which reduceswear
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
Segregation Effects due to Kiln Rotation
Fine clinker
Coarse clinker
Coarse clinker side, low pressure drop
Fine clinker side, high pressure drop
Tendency to develop a red river on the coarse and fine side
A Langley Holdings Company Claudius Peters Projects GmbH
Clinker Cooling Curve
Big influence at the front of the cooler
Small influence at the end of the cooler
A Langley Holdings Company Claudius Peters Projects GmbH
Red River of Traditional Cooler
Typical Grate Cooler Troubles:
� Hot fine clinker reaches end of the cooler
� High wear on grate plates
� Hot air flows in exhaust air duct
� Clinker is not cold at the end of the cooler
� Recuperation is not optimum.
NO Grate cooler can influence the clinker flow over the cooler width!
YES ETA CAN!
A Langley Holdings Company Claudius Peters Projects GmbH
Aeration Scheme
Recuperation zone Cooling zone
1. High Efficiency –Module (HEM)
2. Controlled Side Aeration (CSA)
3. Individual Stroke Length
CSA
CSA
HEM1,2m 1,4 m 2,2m 2,2m 3,3 / 4,4 m
A Langley Holdings Company Claudius Peters Projects GmbH
Process Optimized Aeration
1: HE-Module (HEM):
Small aeration fields ensure precise and adjustable aerationin the drop zone
2: Aeration Chambers:
Small aeration chambers at the cooler front, bigger chambers further down the cooler; >> corresponds with the clinker cooling curve
3: Chamber Side Aeration (CSA):
Longitudinal Chambers Left and Right to prevent red river
4: Individual Stroke length:
Shorter stroke length on the sides to prevent red river
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
Modular Design
� fully modular constructed� standard sizes� flexible module arrangement for existing plants� pre-assembled modules to site
Essential design features:
A Langley Holdings Company Claudius Peters Projects GmbH
Semi-Modular Design
horse shoerefractory
lower side walls
partition walls
HE-Modulesteel work
lane unitsWith sealings
air distribution withmeasuring devices
roller units withcross traverse
hydraulic drive
HE-ModuleGrate plates
Possible local or customer supply
CP supply
A Langley Holdings Company Claudius Peters Projects GmbH
Sample of Revamping of an Existing Grate Cooler Type „Fuller“
A Langley Holdings Company Claudius Peters Projects GmbH
Erection of ETA Units
ETA Units are brought in one after the other
A Langley Holdings Company Claudius Peters Projects GmbH
Overview Unit vs. Modular vs. Semi-Modular
Unit Modular Semi-Modular
Portion CS / local Low Lowest High
Pre-manufactured Yes Yes No
Key components CPP CPP CPP
Steel work / lower part
Existing CPP Local / Customer
Quality control 100% CPP 100% CPP Partial Local
Assembly Shortest Short Extended
Handling / transport cost
Medium Higher Lower
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
Clinker bed = Power consumption= Cooler efficiency
Modern ETA CoolerTraditional
Grate cooler
Bed height 800 mm 600 mm
Retention Time@ 45 t/d/m²
35,8 min 26,9 min
Power consumption 6,76 kWh/t clinker 5,9 kWh/t clinke r
Cooler efficiency 77,6% 74,1%
Comparison ETA versus Grate cooler
A Langley Holdings Company Claudius Peters Projects GmbH
Comparison ETA versus Grate cooler
A Langley Holdings Company Claudius Peters Projects GmbH
Comparison ETA versus Grate cooler
A Langley Holdings Company Claudius Peters Projects GmbH
Introduction ETA Cooler
1. CP Clinker Coolers
2. ETA Cooler
� Self Protected design
� Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References
A Langley Holdings Company Claudius Peters Projects GmbH
Overview ETA References
ETA Cooler sold 56
Replacing conventional cooler 19
Replacing satellite cooler 4
Behind wet kilns 3
Cooler in backward design 2
ETA Cooler as stage cooler 17ETA Cooler as a base for waste heat recovery
16
ETA Cooler in operation 42
Min. Capacity 700 t/d
Max. Capacity 13.000 t/d
A Langley Holdings Company Claudius Peters Projects GmbH 31
ETA 856 / 1950 (2100) t/d
Performance ( during official 18 days performance evalu ation )
Design Operation
Capacity [t/d] 1950 1917
Clinker Outlet [°C above suction temp.] 90 52
Cooling Air Amount [Nm³/kg cl.] 1,670 1,482
Cooler Efficiency [%] 74,0 75,8
Spec. el. power consumptioncooling air fans [kWh/t]
5,3 4,39
Ref 46 Holcim Untervaz
ETAHighest Energy Recovery
Lowest Maintenance
A Langley Holdings Company Claudius Peters Projects GmbH
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