CLINKER COOLER OPERATION
Function:
The two primary functions of the clinker cooler are to recuperate as much heat as
possible by preheating the secondary combustion air for the kiln and to efficiently cool
the clinker to a desired handling temperature. Other functions the cooler must provide are
a sufficient air quench to control clinker glass content, and a stable flow of preheated
secondary air to the kiln. The cooler must also be able to operate and survive in a
extremely abrasive high temperature environment.
The clinker cooler is a heat exchanger. A bed of clinker is conveyed progressively
down the cooler by the reciprocating motion of alternate rows of moving grates while
cooling air is pushed through the clinker bed from pressurized under-grate
compartments.
Each under-grate compartment has its own cooling air supply coming from the two
cooling fans.
Fan one provides air for compartments one and two.
Fan two provides air for compartments three and four.
A damper in the air duct to compartment two controls the air distribution between
compartments one and two.
A damper in the air duct to compartment four controls the air distribution between
compartments three and four.
The cooler has two sections, each with its own drive.
The speed of drive one is controlled according to the chamber one pressure, this
pressure is an indication of the clinker bed depth.
The speed of drive two is slaved to the speed of drive one and normally runs 10%
faster than drive one.
The cooling fans have piezometer rings fitted on the inlet cones the pressure is measured
and converted into cubic feet per minute of flow. The flow of air is controlled
automatically by means of PID controller that adjusts the fan dampers to maintain the
desired air flows.
The cooler uses more cooling air than is required by the kiln. To cool the clinker to 100ºF
above ambient will require about 3.6 lbs/air per lb/clinker. The more efficient the kiln
becomes, the less of the air mass will be used for secondary air. The remainder of the air
must be disposed of by other means. The excess air is usually at a relatively low
temperature and of limited use. However, it can be used for the drying and firing the coal
in the coal mill grinding/kiln firing circuit. The excess air is vented to atmosphere
through a dust collector system by means of the cooler vent fan.
The flow through the vent fan is controlled by an automatic control loop that takes the
firing hood pressure signal and the speed or damper of the fan varies to maintain a slight
negative pressure –0.1 in/wc.
Cooler Operation:
Drive speed controlled by the compartment one under-grate pressure in order to
maintain the desired bed depth. It is very important that the bed depth be kept at a
more or less constant level. When the bed depth changes the heat recuperation
changes. The bed depth should be as deep as possible without impeding the flow of
air through the clinker, the ideal is 18 – 20 inches.
The cooling fans should whenever possible, be operated in automatic in order that the
quantity of air to the compartments remains the same at all bed depths.
At the discharge end of the cooler there is a hammer crusher that breaks down oversized
lumps of clinker and coating. From there the clinker enters the clinker transport and
passes to the storage.
Cooler Instrumentation:
The cooler is a vital part of the kiln system and has a great influence on the production
capacity and fuel economy of the kiln. In order to obtain maximum efficiency from the
cooler it is vital that good operating parameters are used and maintained stable.
The vent fan is used to maintain a slightly negative pressure at the kiln firing hood.
The fan damper controller is connected to the hood pressure transmitter to maintain a
set pressure in the hood.
The bed depth is controlled by the under-grate pressure in the first compartment. The
speed of the drive is controlled by a pressure transmitter to maintain a set pressure in
the compartment. An increase in the bed will cause an increase in the pressure,
signaling an increase in the drive speed to bring the pressure back to set point.
The cooling fans have constant volume controls to maintain a constant airflow as bed
resistance changes. Piezometer rings on the fan inlets sense inlet suction pressure,
which is a function of the airflow entering the fan, the controller adjusts the damper to
maintain a set inlet pressure.
Start Up:
Assuming that the kiln is coming on line.
Start the clinker and dust transport conveying system and check operation.
Start the hammer crusher.
Start the cooler vent fan with damper closed.
Start the cooling fans with dampers closed
Adjust the vent fan damper to obtain slight negative at the firing hood
Put the vent fan into automatic (- 0.1 inch).
Put the cooling fans in automatic at the required set points.
Start the cooler drives at minimum speed when clinker starts to enter the cooler.
Adjust the cooler fan air-flows according to the kiln production rate.
Gradually adjust the cooler drive speed until the desired under-grate pressure is
achieved then put the controller into automatic.
If the cooler speed and pressure starts to cycle you should take the controller into manual
for a short period and adjust the speed until the pressure is stable then return to automatic.
Adjust the air-flows accordingly as the kiln production is raised.
The speed of cooler drive two is synchronized to run in ratio to drive one.
Shutdown:
Short duration kiln stop.
For short duration stops where we expect the kiln to restart within 0 – 4 hours it is
important that we try to conserve a bed of clinker in the cooler that will both protect the
grate plates and conserve heat for secondary air when the kiln restarts.
Shutdown the kiln as per normal procedure and then shutdown the cooler as follows:
Put cooler fans into manual and set dampers at 0%.
Stop the cooler drives.
Stop cooler fan two.
Put cooler vent fan in manual and adjust the damper to maintain – 1 in/wc pressure.
Run the cooler drives every 30 minutes for 5 minutes to avoid over filling the cooler.
Long duration shutdown of the kiln.
For long duration shutdowns where the kiln is to be cooled down for maintenance etc. it
will be necessary to empty and cool down the cooler.
Shutdown the kiln as per kiln shutdown procedure.
Put cooler fans into manual and set dampers at 0%.
Put cooler drive # 1 into manual and set at minimum speed (approximately 5 spm).
Put the cooler vent fan in manual and adjust the damper to maintain – 1 in/wc
pressure.
When material is no longer entering the cooler from the kiln.
Stop the cooler drives.
Stop the cooler fans.
Stop the cooler vent fan.
Stop the hammer crusher.
Stop the clinker and dust conveying system.
Emergency Situations:
Overfilling due kiln push or coating fall etc.
In the event of a major push or coating fall from the kiln, the cooler can quickly become
overloaded, the operator must take action to prevent a shutdown situation. The degree of
intervention depends on the severity of the push or coating fall.
The operator must take action to prevent the following problems that can lead to a
shutdown.
Overloading the cooler drives.
Overheating and thermal damage to the grate plates and support beams.
Excessive cooler vent temperatures.
Overloading and blocking of the hammer crusher.
Overloading of the clinker transport.
Overheating of the clinker transport.
Necessary actions.
Put the cooler drives into manual.
Increase the drive speeds until the pressure starts to fall.
Maintain the higher drive speed until the heavy load is on the second drive.
Adjust the cooler drive speed to prevent overloading the clinker crusher (usually this
will mean a reduction of speed by at least 30%.
If needed, the kiln speed can be taken out of synchronization and the speed reduced
for a short period. (maximum 15 minutes)
When the cooler pressures and clinker breaker amps return to normal put the cooler
drive back into automatic.
Overheated or red grate plates:
Check air flows are sufficient.
Check that the bed depth is not too thick (high compartment pressure). When the bed
is too thick the flow of air will not pass through the plates and will take the path of
least resistance, plates with less bed, to the next compartment (leaky seals) or through
the side seals along the walls.
Check that the bed is not too thin (low compartment pressure). A thin bed can lead to
hot clinker from the kiln falling directly onto bare plates. The bed depth should not be
less than 10 inches.
Loss of cooler vent fan:
Loss of the cooler vent fan will result in serious over pressure of the cooler and firing
hood. This is dangerous for personnel in the area and can cause serious thermal damage
to the kiln outlet seal.
Immediately reduce the cooling fan 2 to minimum air flow by taking the controller
into manual and closing the damper.
Reduce the air flow to cooling fan 1 till the firing hood pressure is showing slightly
negative.
Put the cooler drive into manual and maintain normal speed.
Try to restart the vent fan if it is showing available to start, if not send electrical and
mechanical to investigate and/or rest.
If the fan can not be restarted within approximately 5 minutes the kiln and cooler
must be shutdown.
Loss of cooling fan # 2
If cooling fan # 2 trips out or is stopped for any reason the kiln can continue to operate
for a period if the following steps are implemented.
Increase the airflow to fan # 1 as much as possible.
Call for electrical and mechanical assistance to find the cause.
If the fan can not be restarted within a short period the kiln production should be
reduced.
The under-grate compartments must be inspected to make sue that the plates are not
overheating and there is not excessive material spillage. Excessive material spillage
can cause damage to the side seals.
Loss of cooling fan # 1
If cooling fan # 1 is lost and cannot be restarted within 5 minutes the kiln must be
shutdown due to the high temperatures. If cooling fan # 1 trips.
Stop the cooler drive to prevent hot new clinker coming into contact with the grates.
If the fan cannot be restarted within 5 minutes the kiln must be shutdown.
Snowman:
Snowmen are the result of buildups of sticky clinker on the shelf, or first grates, in the
cooler. Variations in mix and/or too high a temperature of the clinker as it drops from the
kiln, result in an excessive liquid phase that forms the matrix of the solidified clinker. An
extreme condition would be that of having the clinker literally like lava, flowing over the
grates, completely blinding the grates, and damaging grates, supports, drives, etc. This
can happen and requires jack-hammering the cooler free before it can be repaired.
Prevention of Snowmen:
Maintain stable chemistry
Do not over burn the kiln for long periods.
Maintain adequate air volume to chamber # 1
