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. The clinker bed can be transported using two types of grates. The dust falls on the coolerand blows back into the kiln which is. Installation of latest generation high efficiency clinker. Less snowman tendency less falling through of clinker.
Us58748a method and apparatus for preventing formation of. In addition the cooler should be less complicated, more efficient and easier to operate than other grate coolers on the market. Snowmen disappear in florida more uptime and efficiency. Latest developments in high efficency clinker cooling. Best practices in energy efficiency in cement sector under. Even kilns within the same plant are often found to produce quite different clinker, although fed with the same raw mix. I believe if you get too many of them it is an indication of overheating or poor distribution in the kiln.
The new pyrofloorspl reg clinker cooler with low maintenance. Thus, in terms of overall operation costs, the eta cooler has. 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 formation is related to raw mix composition and operating conditions. The selected cooler fans are custom designed for handing the increased input temperatures. The eta coolers high clinker bed and the intelligent aeration scheme deliver optimum recuperation efficiency, resulting in less fuel required to fire the kiln. As layer after layer of the fines fuse onto the clump of clinker, a snowman will grow upwardly into a stalagmitelike structure. Data into operational intelligence, data management, data rich. The clinker retains some liquid phase after falling into the cooler and this causes the buildup of a snowman.
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. Fines then stick to the top surfaces of these clumped clinker. This paper present the new features of the pyrofloorspl reg clinker cooler and their. 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. Us58748a method and apparatus for preventing formation. 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. 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. It is a wellknown fact that the granularity of clinker products can vary considerably from one cement plant to another. 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. Third generation coolers the clinker cooler is a critical component in the cement manufacturing process and has been an area of great.
In the eta cooler this process is slowed down by the lane which is delaying the forward movement of the material. The airquenching shaking grate clinker cooler was developed more than 20 years ago as an improved heat recuperating cooler for use with rotary kilns. The cleaning air can be selectively supplied to a portion or portions of the cooler inlet grate. The result is a cooler representing the highest standard in clinker cooling technology at an attractive investment level.
As usual, the kiln hood and cooler cooer is designed for lowest dust recirculation and hence clear flame. 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. Detect combustion changes, waste fuel imbalance, red river and snowman formation in an instant. Method and apparatus for preventing formation of snowmen. European cement research european cement research academy. Flsmidth crossbar cooler the latest standard in clinker. To avoid material build up and snowman formation it is necessary to install air blasters for. Rings, buildups, formation in cement kiln clinker 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. Full text of holderbank cement engineering book see other formats holderbank cement seminar 2000 process technology ii kiln systems clinker coolers u. Key benefits no snowman formation with abc inlet high reliability. In cement industry, a snowman is the formation of clinker as a heap which falls out of a hot kiln into a cooler compartment.
The basic idea was to develop a cooler in which conveying of clinker and air distribution systems are separated. The maintenance costs are lower than they would be with a grate cooler, with substantial reduction in wear parts as well. Publishers pdf, also known as version of record link back to dtu orbit citation apa. The cooler is built from standard modules with the length determined by capacity and the height determined by required temperature drop. The cement kiln system is designed to accomplish these processes. Formation of these clinker balls is associated with heavy sulphur cycles on from cement 3 at alexandria university. 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. Dusty clinker formationwhen the kiln is dusty the snow man problem starts. 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. Two units will prevent snowman formation in any cooler. Moreover, the cooler operates with no risk of snowman formation as there are air blasters installed at front and side walls. Flsmidth crossbar cooler the latest standard in clinker cooling. 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.
There what occurs when molten, or near molten material is rolled along the inside surface of the kiln or cooler. Sometimes, large lumps of kiln coating may act as a base for the formation of snowmen. The flsmidth crossbar cooler represents the latest evolution in clinker cooling technology. Technical university of denmark, department of chemical and biochemical engineering. One turboflow system may keep an entire one floor preheater wall buildup free.
Following the stationary inlet kids, the cooler is divided into separately aerated compartments. On the other hand the cooler construction and the distribution of cooling air at the cooler inlet affect the clinker transport. 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. Formation of these clinker balls is associated with heavy. Conditions like snowman and red river in the cooler can be detected. These measures are usually taken to improve clinker quality and lower production costs but they also reduce the energy use and air. Snowman formation discharge of sticky clinker containing residual liquid from kiln causing buildup at cooler inlet. What are the reasons for snowman formation in clinker cooler and.
Method and apparatus for preventing formation of snowmen and. 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. Sometimes the buildups break loose and choke the cyclones, kiln or the. 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. In the eta cooler this process is slowed down by the lane.
It is based on proven and refined flsmidth cooler technology. General considerations the clinker cooler has the following tasks to fulfil. 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. What is the formation mechanism of snowman, rhino horn. On the other hand in reciprocating grate coolers clinker is transported by stepwise pushing of the clinker bed. Integrated pollution prevention and control ippc reference. Is a formation of large buildup on cooler first grate static grate or kiln discharge wall where the clinker falls from the kiln. Snowman formation is caused by the high efficiency and therefore secondary air temperature of. Turboflow is activated either automatically, manually or remotely. 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. 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. In addition the cooler should be less complicated, more efficient and. The summation of all these losses are termed or referred to as cooler loss. Thermographic system the durag thermography system is an optical pyrometer based on video data processing.
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. Chunky material onsistent material flow is an essential. 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. 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. These measures are usually taken to improve clinker quality and lower production costs but they also reduce the energy use and air emissions. As usual, cds fan pressure is much lower and aeration stronger. Rolling a plastic, nearmolten material will tend to round all the corners off. Snowman formation clinker cooler cement technology general.
Pdf cement plant operation handbook jorge pinedo sanchez. In both the kilns, we are facing very big unshaped clinker coating coming from kiln inlet to pre burning zone and disturb. The sf cooler has a clinker conveying device installed above an entirely fixed grate. Snowman formation in clinker cooler if this is your first visit, be sure to check out the faq by clicking the link above. Any way t he problem of snowman is due to high fuel input to the pryosystem. The dvta 200 video and thermography system is a modular system specially developed for use. 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. Method and apparatus for preventing formation of snowmen and removing lumps of coating in clinker coolers. 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 material buildups lead to final product for transport, has unique issues. Snowman formation is the basic reason for your problem, after maintanance. Sometimes the buildups break loose and choke the cyclones, kiln or the clinker cooler. 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.
A common problem occurs where clinker discharges from the kiln and falls into the clinker cooler. In traveling grate coolers a traveling grate transports clinker. Snowman is clinker pile which can be formed due to. 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. 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. 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. Jul 06, 2019 the clinker moves smoothly from the static grate cds without previous snowman formation. 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. The clinker moves smoothly from the static grate cds without previous snowman formation.
Flame form and position main burner position and state clinker formation. Snowman formation clinker cooler cement technology. Grate cooler industrial clinker cooler and clinker grate cooler. Snowman formation and prevention infinity for cement equipment. Snowman formation clinker cooler free download as pdf file. Our clinker coolers do the job they are designed for. Becase, your cooler is designed to cool and convey clinker of.
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