Cooler
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Cooler Efficiency Attapong Sathitmanothum Cement (Thung Song) 30 June 2005 Siam Cement Industry Co.,Ltd.
Clinker Cooler : Grate System Tertiary Air
Excess Air
Secondary Air
Hot clinker
Cooled clinker Cooling Air
Siam Cement Industry Co.,Ltd.
2
Cement and Concrete Technology 2005’
1
Grate Cooler Heat Losses 1. Excess air 2. Clinker leaving the cooler 3. Radiation loss
Siam Cement Industry Co.,Ltd.
3
88% 9% 3%
Cement and Concrete Technology 2005’
Major Types of Cooler Loss • Total Cooler Loss – Reference temperature = 0 deg.C
• VDZ Cooler Loss – Cooling air temperature as reference point
• Standard Cooler Loss – Normalized combustion air 1.155 kg/kg clinker – Cooling air temperature as reference point
Siam Cement Industry Co.,Ltd.
4
Cement and Concrete Technology 2005’
2
Cooler Efficiency Eff. = 100 –
100 x Cooler Loss Hot clinker + Cooling air
Cooler loss = TKO x CPTKO + MEX x TEX x CPTEX + RA TKO
: temperature of clinker leaving cooler 1450 oC
TEX
: temperature of excess air
CPTKO : specific heat of clinker at temp. TKO (oC) CPTEX : specific heat of air at temp. TEX (oC) RA
: radiation loss
Siam Cement Industry Co.,Ltd.
5
Cement and Concrete Technology 2005’
VDZ Cooler Efficiency Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power) Max. heat release clinker Max. heat release clinker is Heat content of clinker at the kiln discharge temperature 1450 deg.C
Siam Cement Industry Co.,Ltd.
6
Cement and Concrete Technology 2005’
3
Example of Cooler Efficiency Tertiary Air 0.79 kg/kg, 770 oC
Excess Air 1.6 kg/kg, 251 oC
Secondary Air 0.41 kg/kg, 1062 oC
Hot clinker 1 kg, 1400 oC
Secondary Air 0.41 kg/kg, 20 oC
Cooled clinker 1 kg, 122 oC Tertiary Air 0.79 kg/kg, 20 oC Excess Air 1.6 kg/kg, 20 oC 7
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
Cooler Heat Balance Heat input
kg/kg
oC
kcal/kg oC
kcal/kg 367
Clinker
1.000
1400
0.262
Dust 8%
0.080
1400
0.262
29
Secondary air
0.410
20
0.237
1.9
Tertiary air
0.790
20
0.237
3.8
Excess air
1.600
20
0.237
7.6
6kWh/t
x 0.86
x 0.85
Power cons. Sum
4.4 414
Heat output
kg/kg
oC
kcal/kg oC
Clinker
1.000
122
0.193
24
Dust
0.080
1062/770
0.234/0.229
16
kcal/kg
Secondary air
0.410
1062
0.261
114
Tertiary air
0.790
770
0.225
155
Excess air
1.600
251
0.243
98
Radiation
7
Sum Siam Cement Industry Co.,Ltd.
414 8
Cement and Concrete Technology 2005’
4
Total Cooler Loss Reference Temperature = 0 deg.C • Excess air
98 kcal/kg.cli
• Clinker leaving cooler • Radiation • Total cooler loss
24 kcal/kg.cli 7 kcal/kg.cli 129 kcal/kg.cli
9
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
VDZ Cooler Loss Reference temp. = cooling air temp (20 deg.C) • Excess air
90.4 kcal/kg.cli oC
– Excess air at 251 – Excess air at 20 oC
+98 kcal/kg.cli -7.6 kcal/kg.cli
• Clinker leaving cooler
20 kcal/kg.cli
oC
– Clinker at 122 – Clinker at 20 oC (0.189 x 20)
• Radiation
7 kcal/kg.cli 117 kcal/kg.cli
• Total cooler loss
Siam Cement Industry Co.,Ltd.
24 kcal/kg.cli -4 kcal/kg.cli
10
Cement and Concrete Technology 2005’
5
Heat absorption of combustion air Hot clinker from kiln
363 kcal/kg.cli
oC
- Hot clinker at 1400 - Hot clinker at 20 oC (0.189x20)
367 kcal/kg.cli -4 kcal/kg.cli
Power of Fan Clinker leaving cooler
+4.4 kcal/kg.cli -20 kcal/kg.cli
- Clinker at 122 oC - Clinker at 20 oC (0.189 x 20)
24 kcal/kg.cli -4 kcal/kg.cli
Excess air
-90.4 kcal/kg.cli
Radiation
-7 kcal/kg.cli
- Excess air at 251 oC - Excess air at 20 oC
+98 kcal/kg.cli -7.6 kcal/kg.cli
250 kcal/kg.cli
Heat absorption
or : Hot clinker at 1400 oC +Fan power– VDZ cooler loss Siam Cement Industry Co.,Ltd.
11
Cement and Concrete Technology 2005’
Maximum heat released Maximum heat released
363 kcal/kg.cli
- Hot clinker at 1400 oC
367 kcal/kg.cli
- Clinker at 20 oC
Siam Cement Industry Co.,Ltd.
-4 kcal/kg.cli
12
Cement and Concrete Technology 2005’
6
Cooler efficiency Reference at 0 deg.C Eff. = 100 – = 100 -
100 x Cooler Loss Hot clinker + Cooling air 100 x 129 367 + 13.3
= 66.1 %
13
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
VDZ Cooler Efficiency Reference at cooling air temperature Heat absorption of combustion air
Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power) Max. heat release clinker = 100 – 100 x (117 – 4.4) 363 = 68.9%
Siam Cement Industry Co.,Ltd.
14
Cement and Concrete Technology 2005’
7
VDZ cooler loss vs. Combustion Air
Siam Cement Industry Co.,Ltd.
15
Cement and Concrete Technology 2005’
16
Cement and Concrete Technology 2005’
Example
Siam Cement Industry Co.,Ltd.
8
Cooler Loss vs. Combustion Air
Combustion air (kg/kg cli) Siam Cement Industry Co.,Ltd.
17
Cement and Concrete Technology 2005’
Cooler eff. vs. Combustion Air
Siam Cement Industry Co.,Ltd.
18
Cement and Concrete Technology 2005’
9
End
Siam Cement Industry Co.,Ltd.
19
Cement and Concrete Technology 2005’
10
Clinker Cooler : Grate System Tertiary Air
Excess Air
Secondary Air
Hot clinker
Cooled clinker Cooling Air
Siam Cement Industry Co.,Ltd.
2
Cement and Concrete Technology 2005’
1
Grate Cooler Heat Losses 1. Excess air 2. Clinker leaving the cooler 3. Radiation loss
Siam Cement Industry Co.,Ltd.
3
88% 9% 3%
Cement and Concrete Technology 2005’
Major Types of Cooler Loss • Total Cooler Loss – Reference temperature = 0 deg.C
• VDZ Cooler Loss – Cooling air temperature as reference point
• Standard Cooler Loss – Normalized combustion air 1.155 kg/kg clinker – Cooling air temperature as reference point
Siam Cement Industry Co.,Ltd.
4
Cement and Concrete Technology 2005’
2
Cooler Efficiency Eff. = 100 –
100 x Cooler Loss Hot clinker + Cooling air
Cooler loss = TKO x CPTKO + MEX x TEX x CPTEX + RA TKO
: temperature of clinker leaving cooler 1450 oC
TEX
: temperature of excess air
CPTKO : specific heat of clinker at temp. TKO (oC) CPTEX : specific heat of air at temp. TEX (oC) RA
: radiation loss
Siam Cement Industry Co.,Ltd.
5
Cement and Concrete Technology 2005’
VDZ Cooler Efficiency Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power) Max. heat release clinker Max. heat release clinker is Heat content of clinker at the kiln discharge temperature 1450 deg.C
Siam Cement Industry Co.,Ltd.
6
Cement and Concrete Technology 2005’
3
Example of Cooler Efficiency Tertiary Air 0.79 kg/kg, 770 oC
Excess Air 1.6 kg/kg, 251 oC
Secondary Air 0.41 kg/kg, 1062 oC
Hot clinker 1 kg, 1400 oC
Secondary Air 0.41 kg/kg, 20 oC
Cooled clinker 1 kg, 122 oC Tertiary Air 0.79 kg/kg, 20 oC Excess Air 1.6 kg/kg, 20 oC 7
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
Cooler Heat Balance Heat input
kg/kg
oC
kcal/kg oC
kcal/kg 367
Clinker
1.000
1400
0.262
Dust 8%
0.080
1400
0.262
29
Secondary air
0.410
20
0.237
1.9
Tertiary air
0.790
20
0.237
3.8
Excess air
1.600
20
0.237
7.6
6kWh/t
x 0.86
x 0.85
Power cons. Sum
4.4 414
Heat output
kg/kg
oC
kcal/kg oC
Clinker
1.000
122
0.193
24
Dust
0.080
1062/770
0.234/0.229
16
kcal/kg
Secondary air
0.410
1062
0.261
114
Tertiary air
0.790
770
0.225
155
Excess air
1.600
251
0.243
98
Radiation
7
Sum Siam Cement Industry Co.,Ltd.
414 8
Cement and Concrete Technology 2005’
4
Total Cooler Loss Reference Temperature = 0 deg.C • Excess air
98 kcal/kg.cli
• Clinker leaving cooler • Radiation • Total cooler loss
24 kcal/kg.cli 7 kcal/kg.cli 129 kcal/kg.cli
9
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
VDZ Cooler Loss Reference temp. = cooling air temp (20 deg.C) • Excess air
90.4 kcal/kg.cli oC
– Excess air at 251 – Excess air at 20 oC
+98 kcal/kg.cli -7.6 kcal/kg.cli
• Clinker leaving cooler
20 kcal/kg.cli
oC
– Clinker at 122 – Clinker at 20 oC (0.189 x 20)
• Radiation
7 kcal/kg.cli 117 kcal/kg.cli
• Total cooler loss
Siam Cement Industry Co.,Ltd.
24 kcal/kg.cli -4 kcal/kg.cli
10
Cement and Concrete Technology 2005’
5
Heat absorption of combustion air Hot clinker from kiln
363 kcal/kg.cli
oC
- Hot clinker at 1400 - Hot clinker at 20 oC (0.189x20)
367 kcal/kg.cli -4 kcal/kg.cli
Power of Fan Clinker leaving cooler
+4.4 kcal/kg.cli -20 kcal/kg.cli
- Clinker at 122 oC - Clinker at 20 oC (0.189 x 20)
24 kcal/kg.cli -4 kcal/kg.cli
Excess air
-90.4 kcal/kg.cli
Radiation
-7 kcal/kg.cli
- Excess air at 251 oC - Excess air at 20 oC
+98 kcal/kg.cli -7.6 kcal/kg.cli
250 kcal/kg.cli
Heat absorption
or : Hot clinker at 1400 oC +Fan power– VDZ cooler loss Siam Cement Industry Co.,Ltd.
11
Cement and Concrete Technology 2005’
Maximum heat released Maximum heat released
363 kcal/kg.cli
- Hot clinker at 1400 oC
367 kcal/kg.cli
- Clinker at 20 oC
Siam Cement Industry Co.,Ltd.
-4 kcal/kg.cli
12
Cement and Concrete Technology 2005’
6
Cooler efficiency Reference at 0 deg.C Eff. = 100 – = 100 -
100 x Cooler Loss Hot clinker + Cooling air 100 x 129 367 + 13.3
= 66.1 %
13
Siam Cement Industry Co.,Ltd.
Cement and Concrete Technology 2005’
VDZ Cooler Efficiency Reference at cooling air temperature Heat absorption of combustion air
Eff.VDZ = 100 – 100 x (VDZ Loss - Fan Power) Max. heat release clinker = 100 – 100 x (117 – 4.4) 363 = 68.9%
Siam Cement Industry Co.,Ltd.
14
Cement and Concrete Technology 2005’
7
VDZ cooler loss vs. Combustion Air
Siam Cement Industry Co.,Ltd.
15
Cement and Concrete Technology 2005’
16
Cement and Concrete Technology 2005’
Example
Siam Cement Industry Co.,Ltd.
8
Cooler Loss vs. Combustion Air
Combustion air (kg/kg cli) Siam Cement Industry Co.,Ltd.
17
Cement and Concrete Technology 2005’
Cooler eff. vs. Combustion Air
Siam Cement Industry Co.,Ltd.
18
Cement and Concrete Technology 2005’
9
End
Siam Cement Industry Co.,Ltd.
19
Cement and Concrete Technology 2005’
10
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