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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