eta cooler 0204
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ETA cooler new one in cement industryTRANSCRIPT
Technology you can trust...
h-cooler- the new generation of
clinker cooler
About...
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Claudius Peters TechnologiesGmbH, Germany and ClaudiusPeters Technologies S.A., Franceare part of the TechnologiesDivision of Claudius Peters GroupGmbH, headquartered inBuxtehude, near Hamburg,offering technologies in thefield of materials handlingand processing, providingturnkey and semi-turnkeysystems to a wide range ofindustries. Claudius Peters GroupGmbH is a wholly ownedsubsidiary of Langley Holdingsplc, a privately controlled UKengineering group, with regionaloffices in the Americas, Europe,China and the Far East.
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Clinker Cooling has evolved...
With the ongoing innovation in cooler
technology since the 1950s, the
capacity of cement plants has
increased as their maintenance costs
and the wear and tear on parts have
reduced. These improvements have
largely been driven by design and
process technology solutions. At the
forefront of this effort for the past five
decades, Claudius Peters has been
responsible for many of the innovative
new developments that have led to
these advances.
Such developments include the
introduction of the hydraulic drive and
the roller crusher, as well as the wear-
free CSS (compact swing support). The
latest generation Claudius Peters
cooler, christened the -Cooler
incorporates a highly efficient transport
system. With a significantly reduced
number of parts, and no conveying
elements in the clinker bed,
maintenance costs and wear and tear
have been dramatically minimised.
Introduction
For over half a century, Claudius Peters
has had an established reputation as a
cooler specialist in the global cement
industry. The company began by
marketing in Europe the grate cooler
under licence from Fuller. Through its
own advancements and optimisations
on this design, Claudius Peters
developed its own grate cooler, which is
now in operation all over the world.
Many of these improvements - such as
the hydraulic grate drive (1975) and the
roller crusher (1979) - are now standard
elements for all cooler manufacturers
today.
In recent years, Claudius Peters' efforts
have been focused on achieving an
optimum clinker distribution over the
width of the reciprocating grates -
incorporated in the cross motion grate
in 2000 - as well as a fall through free
cooler with a low as construction height
as possible. This was achieved in a
cooler in 2001.
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Static Inlet
HE Module Aeration
The complete lower section of the
h-Cooler is a modular design. Just two
different lengths of standard modular
elements are combined to optimise
cooler sizes from 1,000-12,000t/d. The
required cooler width is achieved by
modular design of the transport lanes.
Each module is delivered completely
pre-assembled, thereby minimising
erection times on site. The -Cooler
can be installed in the housings of
existing grate coolers with only minor
Static Inlet
The HE (High Efficiency) module
narrows in the direction of the inlet by
means of refractory concrete to achieve
an optimal clinker distribution on the
subsequent dynamic lanes.
With the HE module, which consists of a
static inclined grate, the risk of
snowmen forming is virtually eliminated,
while also ensuring a permanent clinker
layer on the module itself. The aeration
of the HE module is carried out via small
sections and the air quantity can be
adjusted by means of manual flaps.
Due to the flexibility of the air
distribution, it is possible to coincide
with the corresponding kiln discharge
conditions and the changing
environment due to the use of different
fuels and raw materials.
a Revolution in Clinker Cooling �
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FEATURES
Example of transport principle for a 5-lane -Cooler
modifications. The conversion of an
existing grate cooler into a -Cooler is
therefore possible.
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Depending on the required throughput
capacity, a corresponding number of
transport lanes are installed side by
side, each supported on rollers.
Due to the parallel, individually driven
and aerated transport lanes, the flow
behaviour and material speed at the
sides can be actively influenced,
thereby preventing a red river.
The slots for the air supply are
integrated in the transport lanes by
adapting the Mulden plate principle.
Each transport lane is sealed by means
of a labyrinth, which eliminates the need
for a dust removal system. This together
with the fact that the transport
system can be laid
horizontally makes
the -Cooler
d e s i g n
Transport System
The -Cooler uses a new transport
system for the cooler technique. This
system is based on the well proven
'walking floor' system that has long been
tested for bulk materials handling.
The -Cooler consists of parallel
transport lanes which are moved
together in the direction of the clinker
transport (forward stroke) and
individually or alternatively in
groups backwards
(backward stroke).
Cold clinker protects against hot material
Extremely compact design
No dust removal system required
Complete autogenous wear protection
Long strokes = low grate speed
Variable stroke length over the cooler width
No conveyor parts submerged in clinker� means less wear - significantly reducing exchange and maintenance work� no obstructions to the clinker flow � constant transport efficiency over cooler life� uniform cooling, since there are no un-aerated areas
Targeted air distribution - Chamber side aeration
� Optimum cooling
� Modular design - quick toinstall
� Optimal transversedistribution of clinker
� Higher transport efficiency
� Low operating costs
ADVANTAGES
extremely compact.
A particular advantage of the system is
that no installations inside the clinker
are needed for the material transport.
Aeration Concept
Since no installations inside the clinker
layer are needed the whole cooler
bottom is fully aerated leading to
uniform cooling and optimum
recuperation.
Additionally the -Cooler makes still use
of the chamber aeration principle - a
well proven aeration concept in grate
cooler design. However, in contrast to
reciprocating grate coolers the -design
allows for a longitudinal division into
chambers, which gives the advantage
of chamber side aeration, improving
cooling at the critical side areas of the
cooler and reducing the risk of red
rivers.
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(eta) – the universal symbol for efficiency
A roller crusher for a 4,200-t/d operation
Drive System
The -Cooler is equipped with a
hydraulic cylinder drive. Depending on
the number of transport lanes, the
structure is modular and uses standard
parts, which do not require major
maintenance or adjustment. The
hydraulic cylinders attributed to each
transport lane make a long stroke
possible, which is controlled by an
integrated continuous position
measuring system.
The Claudius Peters RollerCrusher- The Original!
The roller crusher consists of air-cooled,
hydraulically or mechanically driven
rollers, whose operating width matches
the width of the cooler grate.
The number of rollers depends on the
clinker capacity to be crushed. Each
roller is equipped with high wear and
temperature resistant cast crushing
rings. The roller crusher is a modular
design for capacities up to 12,000t/d.
For high temperature crushing the roller
crusher is equipped with a cooling air
fan.
Due to the crushing method, the roller
crusher is able to continuously crush
large lumps up to 2 metres in diameter
without stalling. The low rotational
speed of the rollers guarantees the
highest possible lifetime and low
maintenance costs.
Features of Roller Crusher
� Can operate right behind the
recuperator zone� Slow roller speed, therefore minimal
wear� No refractory damage� Minimum dust generation� Long crushing life� Uniform particle size reduction over
long service life� Crushing of large lumps without kiln
stoppage� Low power consumption� Fully automated� Easy maintenance� High availability
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The h--Cooler continues with the
Claudius Peters concept of low
maintenance and repair costs. The
modular design and reduced wear
mean major cost savings are
achievable. The transport system has
no conveying elements within the
clinker layer, which have to be replaced.
Furthermore, no dust removal system is
required, while an extremely low
construction height is called for. This all
adds up to lower investment and
operating costs for the cooler. Also,
again due to the modular design of the
h--Cooler, conversion times are greatly
reduced.
In short, whether it is a new plant or a
conversion, the h--Cooler offers the
most efficient operation in terms of
installation, heat recovery, transport
efficiency, repair costs and
maintenance costs.
Claudius Peters Measuring andControl Systems
Reliable and low cost operation
requires a modern automatic control
system.
Claudius Peters continues to develop
new features for optimum control of
the kiln-cooler process.
Claudius Peters Level Radar
The Level Radar system ensures
online measurement of the clinker
bed height in the cooler inlet, which is
the most critical area of a clinker
cooler.
This development is specifically
designed for abrasive, hot, dusty
conditions and gives a reliable and
exact signal for the clinker bed
height.
Tested over several years in various
plants, the Level Radar systems are
used for controlling the cooler grate
speed. Additionally, the unit is
designed to quickly recognise build-
ups in the cooler inlet area.� Continuous measuring of the
clinker bed height� No delay between appearance,
recognition and reaction� Automatic alarm and control to
prevent overfilling of cooler� Optimum automatic control of the
lane speed, resulting in a stable
combustion air temperature and
a smooth operating kiln� Installation in the kiln hood for all
existing plants
Claudius Peter TemperatureMeasuring Device
The gas temperatures within a clinker
cooler are an important aspect of the
process parameters of the system.
Claudius Peters has developed an
infrared sensor for quickly measuring
the gas temperature:� Infrared measuring sensor with 3°C
per second reaction time� Measuring range from 0 - 800°C
and 500 - 1500°C� Easy installation of air cooler probe� No regular maintenance required� Low investment costs with return of
investment (ROI) in months
Claudius Peter Full StrokeHydraulic Cylinder Drive
The EMC² (ETA Motion Control Centre)
controls and monitors all functions of
the lane/cylinder motion. This hydraulic
control system continuously measures
the position of the cylinders without
contacts to ensure the stroke length
required for each individual lane.
Conclusion
Claudius Peters Technologies GmbH
Schanzenstraße 40
D-21614 Buxtehude
Germany
Tel: +49 (0) 4161 706-0
Fax: +49 (0) 4161 706-270
Claudius Peters Technologies S.A.
34 Avenue de Suisse
F-68316 Illzach
France
Tel: +33 (0) 3 89 313 300
Fax: +33 (0) 3 89 619 525
Claudius Peters (Americas) Inc.
4141 Blue Lake Circle
Dallas, Texas 75244, USA
Tel: +1 972 386 4451
Fax: +1 972 386 4497
Claudius Peters (do Brasil) Ltda.
Rua Coral, 71 - Jardim do Mar
09725-650 São Bernardo do Campo
São Paulo, Brasil
Tel: +55 11 4337 4040
Fax: +55 11 4337 5017
Claudius Peters (UK) Ltd.
320 Kings Road, Reading
Berkshire, RG1 4JG, UK.
Tel: +44 (0)118 966 4555
Fax: +44 (0)118 966 9899
Claudius Peters (Ibérica) S.A.
Avenida de América, 37
1a Planta-Oficina 140
Edificio Torres Blancas
E-28002 Madrid, Spain
Tel: + 34 91 413 36 16
Fax: +34 91 519 69 56
Claudius Peters (Italiana) srl
Via Verdi, 2
I-24121 Bergamo, Italy
Tel: +39 0 35 237 196
Fax: +39 0 35 237 785
Claudius Peters (China) Ltd.
Unit A, 10/F
Two Chinachem Plaza
68 Connaught Road Central, Hong Kong
Tel: +852 2544 1848
Fax: +852 2854 0011
Branch Office:
10/F, Office Block
Hong Kong Macau Centre
No. 2 Chaoyangmen Bei Da Jie
Beijing 100027, P.R. China
Tel: +86 10 6501 3831
Fax: +86 10 6501 3803
Claudius Peters (Asia Pacific) Pte. Ltd.
25 International Business Park
#04-61 German Centre
Singapore 609916
Tel: +65 562 9100
Fax: +65 562 9109
A Langley Holdings Company
www.claudiuspeters.com
CPT 0004/02/04/1 Printed in England
CALCINING . COATING
COOLING . DISPATCH . DOSING
DRY BLENDING . DRYING
GRANULATION . GRINDING
PACKAGING . PNEUMATIC CONVEYANCE
PULVERIZED FUEL SUPPLY
SILO SYSTEMS . STOCKYARD SYSTEMS
TURNKEY PROJECTS
The information contained within this brochure is deemed to be correct at the time of goingto press. Due to the policy of continued improvement, we reserve the right to change anyspecification without prior notice. ERRORS & OMISSIONS EXCEPTED