Clinker Cooling

Cooler Modification- New solution for todays market demands

Alexis Lua - Claudius Peters

The Golden Days

• Do you remember when:

• Cement demand was high

• Competition was low

• Energy prices where stable

• Environmental regulations where minimal

• Investment money was

ready available $$$

• Claudius Peters remembers

Today

• Cement price is low

• Competition is high

• Energy price is high

• Environmental regulations are though

• Investment cuts eminent $

Claudius Peters solution:

• New cooler technology• Efficient = decrease energy

and fuel cost

• Closed system = environment friendly

• Short Return of Investment

My cooler comes from the Golden Days

COOLER MODIFICATION

Increase efficiency

Reduce Maintenance Costs

Always available

SAVE $$$

EFFICIENCY

Modern

ETA Cooler

Traditional

Grate Cooler

Bed height 950 mm 600 mm

Clinker retention Time @ 45 t/d/m² 42,6 min 26,9 min

Power consumption 4,89 kWh/t clinker 4 kWh/t clinker

Cooler Efficiency 77,8 % 73,9 %

MAINTENANCE

ETA Cooler Grate Cooler

Self-protected design

with pebbles and high

clinker layer

Burnt and broken grate plates,

due to direct hot clinker

contact

Hard facing Lane filling with

pebbles

Photo courtesy of client

MAINTENANCE

Photo courtesy of client

Only paint is off

the cooler is ready

for production

After 4 years

After 9 years

MAINTENANCE• Heavy duty rollers

Sig

genth

al /

Sw

itzerla

nd

Sig

genth

al /

Sw

itzerla

nd

02/2

015

Rollers after 6 years after 10½ years of operation

• Designed for fatigue strength and continuous operation

• Slow movement and hard faced surfaced

• Greasing once a year only

• Never replaced a roller since 2004

AVAILABILITYFailure mode:

Modern

ETA Cooler

Traditional

Grate cooler

Failure of one pumpBy-pass is opened, clinker

production continues

Stand-by pump must be

activated

Failure of one lane drive Production continues Production stop

Failure of 2 lane drives Reduced production continues Production stop

DESIGN BONUSETA Cooler-Walking floor tech

No red river Thermal homogenization

No snow man Controlled Side Aeration (CSA)

Cool clinkerLonger drag conveyor and filter life time

Stroke Length2-4 strokes /min = fast cooling , high quality clinker

HE Module flex

airAccurate aeration control

HE Module Cross sealing for max plate lifetime

Experience More than 800 coolers sold

Pioneers More than 100 years of innovation

Smaller HD fan Lower combustion gas vol.

OLD out NEW in

COOLER MODIFICATION

NEW SOLUTION FOR TODAYS MARKET DEMANDS

MODIFICATION

Existing upper steel & refractory

Extension cooler upper part

New parts: pre-asambled ETA lane units

New roller crusher

1

2

3

11 m/s !!

6,3 m/s

13,9 m/s !!!

Separate Bypass ??

Capacity: 3700 t/dAerated Area: 71,1 m²Grate Load: 52,1 (t/d)/m²

MODIFICATION

Existing upper steel & refractory

Modified side walls

New parts: pre-erected ETA lane units

MODIFICATION

Essential design features:

fully modular construction

local fabrication maximized

flexible module arrangement for existing plants

pre-assembled modules to site

Fast installation – minimized kiln shut down time

3 Lane Unit2 Lane Unit

MODIFICATION

Stage Cooler Modification- Quantou Group, China

MODIFICATION

Stage Cooler Modification- Quantou Group, China

Exist. WHR New Mill Air

Heat Content

16,5 MW

Exist. Exhaust Main New WHR

Existing small exhaust New exhaust

MODIFICATION

Stage Cooler Modification- Quantou Group, China

IS MY COOLER SUITABLE FOR MODIFICATION?

CASE STUDYOperation Cost comparison

[Euro/a] [Euro/a]

Capacity 7800 t/d 7800 t/d

Increased capacity @ constant ph fan speed 471 t/d

1: Cooler availability 99,9% 96,3%

Cement production [t/a] 2.571.426 2.478.762

Clinker profit [€/a] 33.801.300 €/a 3.974.700 €/a 29.826.600 €/a 0 €/a

Operation Cost comparison ETA Cooler [Euro/tclinker] Grate Cooler [Euro/tclinker]

2: Cooler efficiency 78,3% 67,0%

Specific Fuel cost [Eur/tclinker] 10,63 11,49

3: Power con. Cooler[kwh/tclinker] [Fans only] 4,34 4,0

Specific power cost [Eur/tclinker] 0,43 0,40

4: Maintenance Cost [Eur/tclinker]* 0,012 0,039

5: Exhaust air Volume [Nm³/kg] 0,788 1,24

Specific power cost [Eur/tclinker] 0,084 0,20

6: Preheater Exit Gas Volume [Nm³/kg] 1,45 1,53

Power consumption [Eur/tclinker] 0,697 0,837

Flexible operation cost [Eur/tclinker] 11,86 €/t 12,97 €/t

Fixed operation cost [Eur/tclinker] 15 €/t 15 €/t

Sales price clinker [Eur/tclinker] 40 €/t 40 €/t

Profit clinker [Eur/tclinker] 13,14 €/t 12,03 €/t

ETA Cooler Existing Polysius SR4840

CAPITAL COST 4.588 TEUR

BENEFIT PER MONTH 331 TEUR

BENEFIT EFFECTIVE IN 9 Month

INTEREST 2% IRR yearly 65,0%

MONTH EXPENSE EXPENSE INCOME NET FLOW DISCO DISCO CUM

% TEUR TEUR TEUR FACTOR FLOW FLOW

1 30% 1.376 - (1.376,3) 1,00 (1.376,3) (1.376,3)

2 0% - - - 0,9983 - (1.376,3)

3 0% - - - 0,9967 - (1.376,3)

4 0% - - - 0,9950 - (1.376,3)

5 0% - - - 0,9934 - (1.376,3)

6 0% - - - 0,9917 - (1.376,3)

7 70% 3.211 - (3.211,3) 0,9901 (3.179,3) (4.555,6)

8 - - - 0,9884 - (4.555,6)

9 - 331,3 331,3 0,9868 326,9 (4.228,7)

10 - 331,3 331,3 0,9851 326,4 (3.902,3)

11 - 331,3 331,3 0,9835 325,8 (3.576,5)

12 - 331,3 331,3 0,9818 325,3 (3.251,2)

13 - 331,3 331,3 0,9802 324,7 (2.926,4)

14 - 331,3 331,3 0,9786 324,2 (2.602,2)

15 - 331,3 331,3 0,9770 323,7 (2.278,6)

16 - 331,3 331,3 0,9753 323,1 (1.955,4)

17 - 331,3 331,3 0,9737 322,6 (1.632,8)

18 - 331,3 331,3 0,9721 322,1 (1.310,8)

19 - 331,3 331,3 0,9705 321,5 (989,3)

20 - 331,3 331,3 0,9689 321,0 (668,3)

21 - 331,3 331,3 0,9672 320,4 (347,8)

22 - 331,3 331,3 0,9656 319,9 (27,9)

23 - 331,3 331,3 0,9640 319,4 291,5 24 - 331,3 331,3 0,9624 318,9 610,3

25 - 331,3 331,3 0,9608 318,3 928,6

26 - 331,3 331,3 0,9592 317,8 1.246,4

27 - 331,3 331,3 0,9576 317,3 1.563,7

28 - 331,3 331,3 0,9560 316,7 1.880,4

29 - 331,3 331,3 0,9544 316,2 2.196,6

30 - 331,3 331,3 0,9529 315,7 2.512,3

31 - 331,3 331,3 0,9513 315,2 2.827,5

32 - 331,3 331,3 0,9497 314,6 3.142,1

33 - 331,3 331,3 0,9481 314,1 3.456,2

34 - 331,3 331,3 0,9465 313,6 3.769,8

35 - 331,3 331,3 0,9450 313,1 4.082,8

36 - 331,3 331,3 0,9434 312,5 4.395,4 37 - 331,3 331,3 0,9418 312,0 4.707,4

48 months calculation

Return on Investment

Preliminary Non Committal

CASE STUDY

CASE STUDY

Replace your CoolerSave € 4.000.000/yr

SUCCESS STORIES

23

JOIN THE ETA EVOLUTION

Sources

• https://www.lottosend.com/blog/can-money-buy-happiness-this-lottery-winner-thinks-so

• http://i.dailymail.co.uk/i/pix/2015/05/03/21/2843B78000000578-0-image-m-154_1430686303059.jpg