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A clinker cooler is a major element of manufacturing clinker. Cement turns into clinker when it dries after moving through a rotary kiln. The raw materials (clay, limestone, and some minor additives) are ground and blended in a raw mill. At this point, the mixture is called kiln feed.
When cement clinker leaves the kiln, it is very hot. The temperature may be as high as 1450°C (2642°F). As the name implies, the clinker cooler lowers the temperature and carries the clinker from the kiln. It also provides heated air for the preheater and the rotary kiln.
The clinker is cooled to a temperature of about 150°C (302°F). The temperature cooling process must be carried out swiftly to preserve the clinker’s quality. Generally speaking, it only takes a few minutes to lower the clinker temperature.
To accomplish this goal, air must be forced through the clinker cooler. Many firms use high-pressure grates to make the cooling flow independent from the clinker bed. This operation keeps the grate quite cool. The clinker’s high temperature also means that heat recovery is called for. Heat clinker cooling fans are usually centrifugal fans. At the start of the process, the fans are high pressure/low flow. At the end of the process, the fans are high flow/low pressure.
What should you expect from a standout clinker cooler? Here are the functions it will perform for your company:
It will provide you with the correct cooling rate for cement clinker. As a result, the clinker easier to grind. The clinker has no time to complete the crystallisation process that would turn it into glass. The clinker can then be converted into a higher quality cement product. The clinker particles will crack after quenching. At this point, they will be much easier to grind.
The cooler will act as a source of hot air for the preheater and the rotary kiln. It will boost the clinker production line’s thermal efficiency. At the same time, the clinker production line’s energy consumption levels decline.
It warms up air to generate waste heat power.
The cooler crushes the clinker. It quenches the clinker to an appropriate (low) temperature so that it can be ground into cement and readied for transport.
As the hot clinker is ejected from the rotary kiln, it falls onto the grate bed. At this phase, the reciprocating grate plate pushes and spreads the hot clinker on the grate bed. It forms a material layer.
Reciprocating Grate Plates. The grate plates are made up of fastened grate plates and movable ones. The plates are positioned in an alternating fashion. The cooler’s transmission drives the movable grate plates (situated between the fastened ones) forward horizontally. The reciprocating motion propels the clinker ahead.
Grate coolers are commonly used to cool clinker. To hurry up the process, cool air blows against the clinker flow into the material layer. The cool air is from the lower portion of the bed to bring the temperature of the clinker down. The hot air that results from this process is then used for burning fuel.
The kiln always has a clinker cooling system due to the following factors:
The cooled clinker is screened. Small pieces are placed into the clinker transporter. Any large pieces are crushed into smaller pieces by the crusher. Then they are re-cooled before entering the transporter.
Clinker transporters are used to carry the clinker to silos or horizontal silos when it is cool enough to carry. The transporters are made to withstand temperatures of about 200°C (392°F).
Once the clinker is sufficiently cooled, it is ready for packaging into bags as cement. The bags are piled onto pallets or placed in large shipping bundles. Cement may also be transported in bulk on cement lorries or goods wagons.
The packing means (either bags in pallet packs or bulk distribution) and shipping options (highway, rail, or by sea) for getting the cement to market is determined by the end user’s location and the volume ordered.
A reciprocating clinker cooler plays a very special role in a cement plant. Magotteaux´s specially designed classic coolers have a role in reliability and efficiency. Smart engineering has been used to couple a classic cooler grate together with unique alloy development. This allows optimum performance. The special Magotteaux patented Magotteaux Mining / Cement / Aggregates / Recycling Hammers + technology provides a longer lifetime as the rear section is better protected. They are available for a variety of different Original Equipment Designer´s Cooler Grates. The cooler also has more efficient heat recovery than a conventional cooler plate. The production performance is much more stable, and it has improved cooling and lower dust emissions.
Our company has developed new designs and alloys. Together, they bring considerable benefits to conventional clinker coolers by increasing the product’s performance as well as its longevity. The clinker cooler is a crucial element of the kiln line. As such, it is required to take on whatever the kiln tosses at it. Reciprocating clinker coolers represent the best option available on the market.
Magotteaux patented Bar Grate Design provides optimal cooling with the following features:
Magotteaux Mining / Cement / Aggregates / Recycling Hammers + cooler grates provide more efficient heat recovery in the clinker cooler than a conventional design.
Magotteaux is your one-stop source where you can get questions answered and advice about any of your clinker cooler concerns. Chat with us about the challenges you are having when processing clinker. Our team has the knowledge and experience to recommend the best solution for your firm’s individual set of circumstances and budget.
Let Magotteaux work with you to find the most suitable methods for processing clinker for your company. We know you want to provide a high-quality product while keeping costs under control. Magotteaux shares those values.
Contact us now to talk about the challenges you are facing with your clinker cooler. We will be happy to help you.