It is basically supplied in two independent entities inlet stationary inclined grate and reciprocating clinker grate cooler which are then joined together for achieving maximum recuperation of heat. Full text of holderbank cement engineering book see other formats holderbank cement seminar 2000 process technology ii kiln systems clinker coolers u. Flsmidth crossbar cooler the latest standard in clinker cooling. The clinker retains some liquid phase after falling into the cooler and this causes the buildup of a snowman. Aug 09, 2018 due to ring formation incomplete combustion takes place which may lead to increased in specific fuel consumption, faster brick wear rate and unsafe kiln operating conditions. To avoid material build up and snowman formation it is necessary to install air blasters for. I believe if you get too many of them it is an indication of overheating or poor distribution in the kiln. On the other hand in reciprocating grate coolers clinker is transported by stepwise pushing of the clinker bed. Flame form and position main burner position and state clinker formation.
Their chemical and mineralogical composition is identical to clinker, but in some cases enrichment up to 3. Their chemical and mineralogical composition is identical to clinker, but in some cases an enrichment up to 3,5% k20 and 3,0% s03 has been noticed. General considerations the clinker cooler has the following tasks to fulfil. Rolling a plastic, nearmolten material will tend to round all the corners off.
Jun 14, 2019 snowman formation have not occured anymore. The clinker formation may start already in the calcining zone, where a certain agglomeration of the fine, solid particles may take place aided perhaps by the presence of low melting alkali salts. Sometimes the buildups break loose and choke the cyclones, kiln or the. Clinker cooler with coanda wing technology more than 35 years of building clinker coolers and over 600 installations worldwide prove that the ikn cooler is at the forefront of technology. Rings, buildups, formation in cement kiln clinker and. On the other hand the cooler construction and the distribution of cooling air at the cooler inlet affect the clinker transport. The cleaning air can be selectively supplied to a portion or portions of the cooler inlet grate.
This conversion confirms the value of the smart blade grate system jkn the design advantages of cooler housing and kiln hood compared to cemprotec cooler on line 1. Third generation coolers the clinker cooler is a critical component in the cement manufacturing process and has been an area of great. Moreover, the cooler operates with no risk of snowman formation as there are air blasters installed at front and side walls. In traveling grate coolers a traveling grate transports clinker. Key benefits no snowman formation with abc inlet high reliability. Data into operational intelligence, data management, data rich. The airquenching shaking grate clinker cooler was developed more than 20 years ago as an improved heat recuperating cooler for use with rotary kilns. Pdf cement plant operation handbook jorge pinedo sanchez. Our clinker coolers do the job they are designed for. In the eta cooler this process is slowed down by the lane.
Snowman formation clinker cooler free download as pdf file. Spurite ring formation in cement kiln or even through belite recorbonation in the kiln these rings are what are thr reasons of ball formation in kiln reasons for clinker snowman formation what are the causes for snowman formation in clinker cooler in cement industry answer snowman iin a kiln. For this, the client replaced an old cooler with a new lvt cooler and awarded standard industrie france with the supply of an airchoc to be integrated during installation of the new cooler. Method and apparatus for preventing formation of snowmen. Dusty clinker formationwhen the kiln is dusty the snow man problem starts. It is a wellknown fact that the granularity of clinker products can vary considerably from one cement plant to another. Fines then stick to the top surfaces of these clumped clinker. The dvta 200 video and thermography system is a modular system specially developed for use. Every eight hours their kiln was creating a snowman and while their pit crew could hydroblast it out of the cooler inlet in less than 30 minutes, a more efficient solution was required. One turboflow system may keep an entire one floor preheater wall buildup free. In cement industry, a snowman is the formation of clinker as a heap which falls out of a hot kiln into a cooler compartment.
Removed by flag of scarborough, on, canada utsrelativity 02. It is based on proven and refined flsmidth cooler technology. What are the reasons for snowman formation in clinker cooler and. Dear, please send the kiln and cooler operation data along with kiln feed chemistry as well as clinker then it will be easy to answer your question. Chunky material onsistent material flow is an essential. The flsmidth crossbar cooler represents the latest evolution in clinker cooling technology. This paper present the new features of the pyrofloorspl reg clinker cooler and their. Becase, your cooler is designed to cool and convey clinker of. Any way t he problem of snowman is due to high fuel input to the pryosystem. The cement kiln system is designed to accomplish these processes. Due to ring formation incomplete combustion takes place which may lead to increased in specific fuel consumption, faster brick wear rate and unsafe kiln operating conditions. Process internal heat recuperation by heat transfer from clinker to combustion air reduce clinker temperature to facilitate clinker handling and storage provide maximum cooling velocity to avoid.
The summation of all these losses are termed or referred to as cooler loss. As usual, cds fan pressure is much lower and aeration stronger. In both the kilns, we are facing very big unshaped clinker coating coming from kiln inlet to pre burning zone and disturb. Even kilns within the same plant are often found to produce quite different clinker, although fed with the same raw mix. Is a formation of large buildup on cooler first grate static grate or kiln discharge wall where the clinker falls from the kiln. Sometimes, large lumps of kiln coating may act as a base for the formation of snowmen. May 27, 2016 clinker, after the prima ry cooler and clinker breaker, is allowed to settle slowly in a bed with heat exchange to air cooled tubes harder et al. Method and apparatus for preventing formation of snowmen and. A common problem occurs where clinker discharges from the kiln and falls into the clinker cooler. European cement research european cement research academy. Snowman formation discharge of sticky clinker containing residual liquid from kiln causing buildup at cooler inlet. Turboflow is activated either automatically, manually or remotely. Thus, in terms of overall operation costs, the eta cooler has.
Clinker with relatively high content of alkali or sulphate. Following the stationary inlet kids, the cooler is divided into separately aerated compartments. Installation of latest generation high efficiency clinker. The eta coolers high clinker bed and the intelligent aeration scheme deliver optimum recuperation efficiency, resulting in less fuel required to fire the kiln. The sf cooler has a clinker conveying device installed above an entirely fixed grate.
These material buildups lead to final product for transport, has unique issues. Us58748a method and apparatus for preventing formation. Latest developments in high efficency clinker cooling. Feb 16, 1999 a method and apparatus for preventing the accumulation of fines and the resulting formation of snowmen in a clinker cooler by applying short duration blasts of high pressure, high velocity air from openings in the cooler inlet grate.
Clinker rings and snowman formation these deposits are formed from small clinker nodules and clinker dust particles, and have a high porosity containing many voids. There what occurs when molten, or near molten material is rolled along the inside surface of the kiln or cooler. In addition the cooler should be less complicated, more efficient and. Sometimes the buildups break loose and choke the cyclones, kiln or the clinker cooler. Dusty clinkermore melt due to alkali or sulfur recycledistorted flamedisintegration of clinker due to reduced conditionsblow back of dust from cooler to kiln and recyclinghigh air flow rate in first portion of clinker, incorrect air distributioncauses. 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. This is regarded as the heat content of cooler vent gas, clinker at exit and radiation in general, cooler radiation for modern cooler will be around 6 kcalkg. Clinker, after the prima ry cooler and clinker breaker, is allowed to settle slowly in a bed with heat exchange to air cooled tubes harder et al. These measures are usually taken to improve clinker quality and lower production costs but they also reduce the energy use and air emissions. Grate cooler industrial clinker cooler and clinker grate cooler. A method and apparatus for preventing the accumulation of fines and the resulting formation of snowmen in a clinker cooler by applying short duration blasts of high pressure, high velocity air from openings in the cooler inlet grate. What is the formation mechanism of snowman, rhino horn. In addition the cooler should be less complicated, more efficient and easier to operate than other grate coolers on the market. Snowman is clinker pile which can be formed due to.
In both the kilns, we are facing very big unshaped clinker coating coming from kiln inlet to pre burning zone and disturb the steady kiln operations. Formation of these clinker balls is associated with heavy sulphur cycles on from cement 3 at alexandria university. Formation of these clinker balls is associated with heavy. The basic idea was to develop a cooler in which conveying of clinker and air distribution systems are separated. Flsmidth crossbar cooler the latest standard in clinker. Publishers pdf, also known as version of record link back to dtu orbit citation apa. The result is a cooler representing the highest standard in clinker cooling technology at an attractive investment level.
Technical university of denmark, department of chemical and biochemical engineering. Jul 06, 2019 the clinker moves smoothly from the static grate cds without previous snowman formation. A variety of cooling grates for cooling cement clinker have been developed and to the surfaces of adjoining pieces of clinker in the cooler and cause the clinker to caking, but the formation of snowmen during the cooling of cement clinker. The selected cooler fans are custom designed for handing the increased input temperatures.
The cooler is built from standard modules with the length determined by capacity and the height determined by required temperature drop. These measures are usually taken to improve clinker quality and lower production costs but they also reduce the energy use and air. Snowman formation is the basic reason for your problem, after maintanance. Snowman formation in clinker cooler if this is your first visit, be sure to check out the faq by clicking the link above. However you might expect that a higher silica modulus and alumina modulus will lead to less snowman formation as the amount of flux in the kiln will be reduced. As layer after layer of the fines fuse onto the clump of clinker, a snowman will grow upwardly into a stalagmitelike structure. Air cannons are commonly used to remedy this phenomenon, but if they experience clogging from backflow, or if they are set in an environment in which it is too hot to properly maintain them, accumulations inevitably form. Preventing snowman formation the challenge at a cernent plant in pakistan was to prevent snowman formation and the free flowing of hot clinker into the cooler. Problem with cooling fan of ikn grate cooler page 1 of 2. Best practices in energy efficiency in cement sector under.
Snowman formation in a grate cooler is the result of some liquid content remaining in the clinker after it falls the airflow around the burnerpipe will cause deposits of fines on top. In the eta cooler this process is slowed down by the lane which is delaying the forward movement of the material. Method and apparatus for preventing formation of snowmen and removing lumps of coating in clinker coolers. Integrated pollution prevention and control ippc reference. Us58748a method and apparatus for preventing formation of. Detect combustion changes, waste fuel imbalance, red river and snowman formation in an instant. Snowman formation is caused by the high efficiency and therefore secondary air temperature of. Two units will prevent snowman formation in any cooler. Snowman formation and prevention infinity for cement equipment.
Snowman formation clinker cooler cement technology general. As usual, the kiln hood and cooler cooer is designed for lowest dust recirculation and hence clear flame. Thermographic system the durag thermography system is an optical pyrometer based on video data processing. Clinker coolers content tasks of clinker cooler theory and definitions grate coolers cooler upgrade clinker crusher rotary coolers holcim group support definitions recuperation is the recovery of heat contained in the hot clinker 0 to 1450c at the kiln discharge to be used in the kiln system for the process substituting fuel. And most of the cement plants are continuing plant operation with day to day issues like low feed rates, low efficiency blending operation, fluctuating clinker quality, cooler problems like snowman formation, kiln ring formation, higher heat and power consumption, low cement strengths etc. The clinker bed can be transported using two types of grates. The maintenance costs are lower than they would be with a grate cooler, with substantial reduction in wear parts as well. The clinker moves smoothly from the static grate cds without previous snowman formation. It was designed to air quench and cool large quantities of hot clinker rapidly, and to recover and return to the kiln a major portion of the heat from the clinker. Remedial measure for snowman formation installation of air blasters in back wall of the cooler and on the sides as well as between the steps of static inlet grates. Conditions like snowman and red river in the cooler can be detected. The dust falls on the coolerand blows back into the kiln which is. Snowmen disappear in florida more uptime and efficiency.
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