Page 1
Martin Uhde
28.08.2007
Clinker Cooler
Page 2 Page 2
Clinker Production
Raw material- Clinker- Cement-
preparation production production
5
9
4
1
6
2 3 6 7 8 10 11
1. Crushing 7. Burning
2. Storage, Mixing 8. Cooling
3. Dosing 9. Storage
4. Grinding 10. Grinding
5. Homogenising 11. Storage, Packing and Loading
6. Preheating, Calcining
Clinker Cooler
Page 3
Clinker Production
“BAZIFA”
6. Preheating, Calcining, TAD Mr. Uhde
7.1 Rotary Kiln Mr. Kroner
7.2 Firing (PC, SZ, KJ) Mr. Hempel
8.1 Clinker Cooler POLYTRACK Mr. Uhde
8.2 Cooler Hydraulic Drive Mr. Milewski
Clinker Cooler
Page 4
Clinker Production
60 °C
• Product Quality
PREHEATER • Recuperation
Calciner
• Cooling
Tertiary Air Duct
Kiln
850 °C
1450 °C
Cooler
100 °C
Clinker Cooler
Page 5
the raw materials:
raw meal clinker
CO2
cumulative wt-% H2O
CaCO3
CaO
1 C3S
C2S
quartz
clay C12A7 C3A
C4AF melt
Fe-ore
T [°C]
0°C 750°C 1500°C
Clinker Cooler
Page 7
the structural reaction:
1600°C C3S growth
temperature [°C]
1400°C
melt formation
freezing
1200°C
C2S-formation
1000°C solid state
reaction
800°C
suspension burning clinker
preheater zone cooler
time, material flow
Clinker Cooler
Page 8 UhdeM 29 Aug 2007 S:\Team\Training\BAZIFA\020-2-Clinkercooler\BAZIFA_Mechanic-Group_POLYTRACK-021-UHD_2007-08-23.ppt
POLYTRACK©
The
POLYSIUS Clinker Cooler
with proven Reliability
Page 10
• Stationary Aeration Floor
Polytrack Design • High Efficient Transport System
• Horizontal Grate Arrangement
• No Clinker Fall Through
• Optimum Clinker Distribution
over the Width
• No Under Grate Clinker Transport
• Modular Component Design
5 tracks
2 modules
Clinker Cooler
Page 11
Aeration and Movement of Clinker
Reciprocating Grate
aeration plate
aeration / conveying plate
POLYTRACK
conveying element
static aeration grate
Clinker Cooler
Page 12
POLYTRACK Design
Clinker Cooler
Page 13
Polytrack - First Grate
Clinker Cooler
Page 14
POLYTRACK© - Movement Principle
Top View of the Grate with Conveying Tracks
Conveying Direction
Clinker Cooler
POLYTRACK
Page 15
- Principle of movement -
Clinker Cooler
POLYTRACK
Page 16
- Principle of movement -
Clinker Cooler
Page 17
POLYTRACK - Video
Clinker Cooler
Page 18
Flexible Height of the Clinker Layer
Low High
Clinker Cooler
Page 19
Influencing the Clinker Distribution
Centre Track is stopped
Clinker Cooler
Page 20
Arrangement of Conveying Elements
Clinker Cooler
Page 21
Conveying Element = Upper Part of Track
Clinker Cooler
Page 22
Aeration Element
Clinker Cooler
Page 23
Aeration Element
Labyrinth air flow
Clinker Cooler
Page 24
Aeration Element
Aeration element housing
Aeration element
Flange connection
for ADS
Bottom of
aeration element
Clinker Cooler
Page 25
Aeration Element
Aeration element
assembled to
Polytrack module
Flange connection
for ADS
Clinker Cooler
Page 26
Support
Clinker Cooler
Page 27
Supporting System
Bearing Block
Longitudinal Girder
(Lower Part of Track)
Clinker Cooler
Page 29
Flat Guide Sealing
Clinker Cooler
Page 30
Flat Guide Sealing
springs
Clinker Cooler
Page 31
Fixed Sealing Part
Clinker Cooler
Page 34
Drive Arrangement
2 4 4 4 4
1 3 3 1
5
• Hydraulic cylinders (1) for each • Longitudinal girders supported by
transportation track row bearing shoes and cross girders (4)
• Cylinders mounted to longitudinal • All cross girders mounted to module
girders (2) and drive cross girders (3) housing
• Coupling of longitudinal girders (5)
Clinker Cooler
Page 35
Hydraulic Cylinders of the Tracks
Clinker Cooler
Page 36
Drive Arrangement
Clinker Cooler
Page 37
Hydraulic unit
2 grates, 5 tracks
Clinker Cooler
Page 38
control room
elektric room
Profibus
SIMATIC S7
DP 1
with Profibus - DP
hydraulic room
Profibus
Control pannel OP170B
DP 2
Control system for proportional-
valves, hydraulic
ET200
controlling of hydraulic unit
local switch hydraulic pumps
ET200
cooler
ET200 ET200
signals grate 1 Signals grate 2
Clinker Cooler
Page 39
Module Dimensions
- Smallest width: 1.5 m
- Possible steps: Multiples of 0.5 m
(1.5 / 2.0 / 2.5 / 3.0 / 3.5 /
4.0 / 4.5 /...... m)
- Module length: 4.8 m
- Shortest length: 7.2 m (1.5 Modules)
- Possible length: Multiples of 2.4 m
Clinker Cooler
Page 40
The Modular Design
MODULE
WITHOUT CONVEYING ELEMENTS
Clinker Cooler
Page 41
Modules of the static grate
Clinker Cooler
Page 42
Cleaning system of the static grate
Clinker Cooler
Page 43
Pre-assembled Polytrack Module
Clinker Cooler
Page 44
Aeration Element and ADS - Air Distribution Switch
Aeration element housing
Aeration element
Flange connection
for ADS
Bottom of
aeration element
Clinker Cooler
Page 45
Polytrack ADS - Air Distribution Switch
Mounting Air outlet
flange
Housing
Pendulum
mounting
Stop
(upper position)
Pendulum
(lower position)
Pendulum
(upper position)
Stop
Air intake (lower position)
Clinker Cooler
Page 46
ADS-System - Characteristics
40
35
ADS
Pressure Drop [mbar]
30
Middle Weight
Pendulum
25
(t=20 mm)
t = 20mm t = 35mm
20 Plate thickness
variation:
15 ADS
15 mm...... 40 mm
Heavy Weight
10 Pendulum
(t = 35 mm)
5
0
0 200 400 600 800 1000 1200 1400
Volume Flow [m³/h]
Clinker Cooler
Page 47
Polytrack ADS - Air Distribution Switch
Clinker Cooler
Page 48
POLYTRACK© ADS-System
Clinker Cooler
Page 49
Polytrack 10 / 2.5 – 3.0 W “ BAZIFA “
Roller Crusher
Kiln Head TAD
Connection
Exhaust Air
Connection
5,000
Grate 1: 14,980 Grate 2: 14,400
Clinker Capacity: 7,000 tpd Cooling Air (installed): 2.07 Nm³/kg Cli
Grate surface: 144.7 m² Cooling Air (Operation): 1.80 Nm³/kg Cli
Specific Load: 48.4 tpd/m² No. of Fans:13 (755,000 Am³/h @ 35°C)
Clinker Cooler
Page 50 Page 50
spec. air volume
[m³/m² min]
Principle of air distribution
100 installed
~ 15%
80
operation
60
40
20
0
0 4 8 12 16 20 24 28 32 36 40
cooler length [m]
Clinker Cooler
Page 51 Page 51
Principle of air distribution
Gradient = f(flow rate air inst.)
spec. air volume
[m³/m² min]
100 installed
~ 15%
80
operation
60
40
20 1 2 3 4 5 6
7 8 9
0
0 4 8 12 16 20 24 28 32 36 40
cooler length [m]
Gradient depends on total amount of installed air
Clinker Cooler
Page 52
Polytrack 10 / 2.5 – 3.0 W – Aeration Diagram
5,000
~72.7 m² ~72 m²
Grate 1: 14,980 Grate 2: 14,400
Clinker Cooler
Page 55
Intermediate Crusher Concept
Clinker Cooler
Page 56
Delta height = f( grate slope)
Height
in m 3
2,5
0°
2 4°
5°
1,5
0,5
POLYTRACK
0 Cooler length
0 5 10 15 20 25 30 in m
Clinker Cooler
Page 57
POLYSIUS Roller crusher
Cooling
air
» Perfect After-Cooling
» Worry-free Operation
» Easy Maintenance
Cooling
air
Clinker Cooler
Page 58
“BAZIFA” Roller Crusher 10 / 5
rotation
S S S C
5 Rollers
10 Tracks
S = screening gap
C = crushing gap
Clinker Cooler
Page 59
Roller Crusher - Air Cooled Shaft
Hydraulic Drive
Clinker Cooler
Page 60
Roller Installation / Removal
Clinker Cooler
Page 61
Roller Installation / Removal
Clinker Cooler
Page 63
Polytrack© References (Feb 01 - Feb 06)
Contract Customer Type Capacity Start up
Feb 2001 Solnhofen Portl., Germany 5/2.0 - 2.0 W (C, 1) 1,800 11 / 2002
Aug 2002 Giant Cement, U.S.A. 7/2.0 - 2.0 W (1) 3,300 03 / 2005
Sep 2002 Tudela Veguin, Spain 6/2.0 - 2.0 W (1) 2,600 11 / 2004
Jan 2003 Fujairah Cem. Ind., U.A.E. 7/3.0 - 3.0 W (C, 1) 5,000 10 / 2004
Apr 2003 Titan Cement, Greece 5/3.5 W (C, 2) 2,100 04 / 2004
Jul 2003 Cimpor, Maroc 6/1.5 (C, 3) 2,800 01 / 2005
Jul 2003 Abyek Cement, Iran 11/4.0 - 2.0 W (C, 1) 8,500 ~05 / 2008
Sep 2004 La Cruz Azul, Mexico 7/2.0 - 2.0 W (1) 3,000 03 / 2007
Nov 2004 Petroquímica, Argentina 7/2.5 W (2) 2,000 ~12 / 2006
Nov 2004 Gilan Sabz, Iran 7/2.0 - 2.0 W (1) 3,400 ~05 / 2008
Jan 2005 Sabzevar, Iran 7/2.0 - 2.0 W (1) 3,400 ~08 / 2008
Apr 2005 Eurocement, Russia 6/1.5 (C) 2,400 05 / 2006
Jun 2005 Cementos Portland, Spain 4/1.5 W (C, 4) 900 10 / 2006
Aug 2005 Neyzar Qom Cement Co., Iran 7/2.0 - 2.0 W (1) 3,300 ~08 / 2008
Aug 2005 TXI Oro Grande, U.S.A. 9/6.0 W 6,000 ~12 / 2007
Feb 2006 Ciment Vicat, Bastas, Turkey 8/3.5 - 2.5 W (1) 5,000 ~10 / 2007
Feb 2006 CIMKO, Turkey 10/4.0 - 2.0 (1) 7,500 ~02 / 2008
Red = Cooler already in Operation 2 = Possible Future Extension
C = Conversion 3 = Extension of an existing Grate Cooler by Install. of a new Grate
1 = 2-Grate Cooler with intermediate Roller Crusher 4 = White Cement
Clinker Cooler
Page 64
Polytrack© References (Mar 06 - today)
Contract Customer Type Capacity Start up
Jun 2006 Jaiprakash Ass., Dalla, India 8/2.5 - 2.5 W (1) 4,500 ~10 / 2007
Jul 2005 United Cement Cooperation 10/2.5 – 3.0 W (1) 7,000 ~11 / 2007
Jul 2006 American Cement, U.S.A. 6/2.0 - 2.0 W (1) 2,700 ~09 / 2008
Aug 2006 YTL, Padang, Malaysia 7/2.5 - 2.5 W (C, 1) 4,000 ~10 / 2007
Sep 2006 Sebryakov Cement, Russia 5/2.5 (C) 2,400 ~11 / 2007
Sep 2006 Urmia Cement Co., Iran 7/2.0 - 2.0 W (1) 3,300 ~09 / 2008
Sep 2006 Cem. del Norte, Honduras 6/2.0 - 2.0 W (1) 3,300 ~11 / 2008
Oct 2006 Industrias Guapán, Ecuador 5/2.0 W (C) 1,300 ~03 / 2008
Oct 2006 Cimpor, Córdoba, Spain 4/4.5 (C) 2,200 ~11 / 2007
Oct 2006 Cimpor, Niebla, Spain 4/3.0 (C) 1,500 ~12 / 2007
Nov 2006 Fujairah Cem. Ind., U.A.E. 10/2.5 - 3.0 W (1) 7,500 ~09 / 2008
Dec 2006 Ambuja, Bhatapara, India 11/4.0 - 2.0 W (1) 7,000 ~12 / 2008
Dec 2006 Cementizillo, Italy 5/4.5 (C) 2,800 ~03 / 2008
Feb 2007 TXI, Hunter, TX, U.S.A. 7/2.5 - 2.0 W (1) 3,500 ~12 / 2008
Feb 2007 Ambuja, Rauri, India 11/4.0 - 2.0 W (1) 7,000 ~03 / 2009
Mar 2007 Coboce, Bolivia 6/2.0 W (2) 1,600 ~03 / 2009
Total of 32 Polytrack Coolers Sold
Red = Cooler already in Operation 2 = Possible Future Extension
C = Conversion 3 = Extension of an existing Grate Cooler by Install. of a new Grate
1 = 2-Grate Cooler with intermediate Roller Crusher 4 = White Cement
Clinker Cooler
Page 66
Clinker Production
“BAZIFA”
6. Preheating, Calcining, TAD Mr. Uhde
7.1 Rotary Kiln Mr. Kroner
7.2 Firing (PC, SZ, KJ) Mr. Hempel
8.1 Clinker Cooler POLYTRACK Mr. Uhde
8.2 Cooler Hydraulic Drive Mr. Milewski
Clinker Cooler
