Claudius Peters

Clinker Cooler Technology

Picture no. 1
 Claudius Peters
Clinker Cooler Technology
Process
Operation
Optimization
of the ETA Cooler
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ETA Cooler

Table of contents

Process, operation and optimization of the ETA Cooler

Technical specification ETA Cooler
Preliminary cooler flow sheet - ETA Cooler
Cooler general layout - ETA Cooler
0 General overview of the ETA Cooler
1 Definitions and terms of the process
2 Definitions and terms of the transport system
3 General process correlations – trend curves
4 Differences between ETA Cooler and grate cooler
5 Control loops of the ETA Cooler
6 Aeration system
7 Gusset monitoring
8 Kiln hood pressure control

Picture no. 3
ETA Cooler

9 Adjustment of the total cooling air

10 Start sequence of the cooler aggregates
11 Alarms
12 Interlocking of the cooler
13 Check list for commissioning
14 Operating conditions
15 Information on the optimization of the cooler operation

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ETA Cooler

Basic data aeration system - ETA Cooler

(Will be adjusted during commissioning)

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ETA Cooler

Aeration scheme - ETA Cooler

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ETA Cooler

Aeration scheme - ETA Cooler

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Process, operation and optimization of the ETA Cooler

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Process, operation and optimization of the ETA Cooler

1 Definitions and terms of the process

Recuperation zone

The recuperation zone is the part of the cooling area from where the cooling air
after heat exchange enters the kiln and / or the tertiary air duct to the pre-
calciner. The air taken by the kiln is called secondary air, whereas the air for the
pre-calciner is called tertiary air.

Cooling zone

This is the rear area of the cooler. In this area the clinker is cooled down to the
clinker outlet temperature. The cooling air in this area becomes cooler exhaust
air.

Picture no. 9
Process, operation and optimization of the ETA Cooler

Figure 1: Partition of the cooling area

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 Process, operation and optimization of the ETA Cooler

Tertiary air

Secondary air
Exhaust air

Figure 2: Partition of cooler air flows

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 Process, operation and optimization of the ETA Cooler

Figure 3: Measuring point for exhaust air temperatur with two thermocouple
to get an average value in the inhomogeneous stream

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Process, operation and optimization of the ETA Cooler

Kiln discharge area

This is the area where the red

hot clinker drops from the kiln
into the cooler. In the ETA
Cooler this is the stationary
inlet section, which is called
HE module.

Figure 4: Red hot clinker dropping on HE module

Picture no. 13
Process, operation and optimization of the ETA Cooler

Mass flow density

In the kiln discharge area

(dropping point of the clinker) the
mass flow density is the highest
and is decreasing towards the
sides of the cooler

Legend of Figure 2

q MD Mass flow density in the kiln discharge area

RB Grate width
937.0009.0001A/00.00.03

Figure 5: Mass flow density

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Process, operation and optimization of the ETA Cooler

Operating conditions of the ETA Cooler

1. Start-up operation
Operation of the cooler from heating-up of the kiln to constant kiln operation

2. Partial load operation

Operation of the cooler below nominal throughput at constant kiln operation

3. Normal operation
Operation of the cooler at nominal throughput and constant kiln operation

4. Shutdown operation
Operation of the cooler after the raw meal feeding has been stopped

The values for the cooling air quantities are given in the data sheet
“Basic data aeration system”.

For the first commissioning, these values are preset as theoretically calculated
values.
If required these values have to be adjusted according to the kiln conditions
during hot commissioning.

Picture no. 15
Process, operation and optimization of the ETA Cooler

Reference fans

Reference fans are cooling air fans in front entrance of the cooler, whose
operating pressure is used as reference value for the control of the speed
for the lanes.

Reference pressure

The reference pressure is the operating pressure of the reference fans,

corresponding to the flow resistance of a defined clinker bed height.

For this pressure there is a rated value and a actual value. Depending on the
individual plant, the operating pressure of a single fan or a calculated value
out of the operating pressures of up to four fans is used. The valence of
each fan can be adjusted.

Picture no. 16
Process, operation and optimization of the ETA Cooler

2 Definitions and terms of the transport system

Forward stroke

Movement of the lanes in material transport direction (piston rods of the

hydraulic cylinders are drawn in).

Backward stroke

Movement of the lanes in opposite to the material transport direction, (piston

rods move out of the hydraulic cylinders).

Stroke cycle

Complete movement cycle, consisting of forward and backward stroke of all

lanes.

Picture no. 17
Process, operation and optimization of the ETA Cooler

Transport efficiency

The transport efficiency is an indicator for the quality of the transport system
with regard to the conveyance of the clinker.

A high transport efficiency means that a high amount of clinker is transported

during each movement cycle towards the roller crusher.

The transport efficiency is mainly influenced by the grain size distribution of

the clinker.

Bed height ratio

The ETA Cooler system requires a minimum clinker bed height to achieve a high
transport efficiency.

The bed height ratio corresponds to the ratio of the clinker bed height during
operation and the width of a single lane. The optimum range is a ratio of min.
1,2.

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Process, operation and optimization of the ETA Cooler

Transport system of the ETA Cooler

Description of motion principle

The ETA Cooler consists of parallel walking lanes and works according to the
walking-floor-principle (pendulum bottom technique).

A motion cycle of the walking lanes always consists of four steps.

Step one forward movement - all walking lanes move forward together.

Step two to four backward movements of the walking lanes. In backward

movement each third walking lane moves backward, i.e. in
backward movement there are always two stationary lanes
inbetween the moving lanes. The number of lanes which are in
backward movement together in steps two to four depends on
the cooler width. The minimum is one lane, the maximum four.

Following see an example of the motion principle of an ETA Cooler with four walking
lanes.

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Process, operation and optimization of the ETA Cooler

Description of motion principle

1
2
3 Start position
4
5

1
2 Forward stroke
3
4 lane 1- 3
5

1
2 Backward stroke
3
4 lane 1 and 4
5

1
2
3 Backward stroke
4 lane 2 and 5
5

1
2
3 Backward stroke
4
5 lane 3
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Process, operation and optimization of the ETA Cooler

Description of the transport principle

Forward movement

During forward movement the clinker on the walking lanes is moved together with
the lanes, there is no relative movement between the walking lanes and the
clinker. During forward movement clinker from the HE module slides onto the walking
lanes. Only the frictional forces between the walls of the cooler and the clinker
on the outer walking lanes must be overcome.

Backward movement

During backward movement of a walking lane, the clinker supports itself mainly
on the neighbouring stationary walking lanes or the cooler side wall. In addition,
the clinker on the front modules supports itself on the HE module. Due to these
holding forces in the clinker layer, the walking lane can slide backward under the
clinker layer and the clinker is moved towards the end of the cooler with the next
forward movement.

In order to provide sufficient holding forces in the clinker layer during backward
movement, the bed height ratio (bed height / walking lane width) must not drop
below a value of 1. Operating experience shows that the bed height ratio should be
within the range above 1,2. In general the following applies:
The higher the clinker bed height, the higher the transport efficiency.

Picture no. 21
Process, operation and optimization of the ETA Cooler
Forward stroke
Forward movement:
- All lanes moved simultaneously
- Clinker moved together with lanes
- No relative movement between walking lanes and clinker
V clinker - Only frictional forces between clinker and cooler walls

F R wall

V clinker

F R Wall
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Process, operation and optimization of the ETA Cooler

Backward stroke
Backward movement:
- Retraction in 3 steps, 2 non-moving lanes between moving lanes
- Clinker supports on neighboring lanes and walls and at HE Module
- Walking lane slides backwards underneath clinker
F pressure

F R bulk solid
Vclinker B
F R bulk solid

H / B ideal = 1,0 - 1,2

Picture no. 23
Process, operation and optimization of the ETA Cooler
Variable stroke length
The maximally possible mechanical stroke length of the installed hydraulic
cylinders is 420 mm. In order to prevent movement into the mechanical end
position, a safety distance of 10 mm has to be kept at both sides. During
operation a maximum stroke length of 400 mm can therefore be used.

In the ETA Cooler the stroke length can be changed via the control system
during operation (online). Mechanical adjustments of the installations are not
required. Each walking lane is driven separately by one or more hydraulic
cylinders and can be controlled separately, i.e. the stroke length of each
walking lane can be selected individually.

The stroke lengths to be adjusted depend on the operation conditions of the kiln
or the cooler. Experience has shown that it is of advantage to clearly reduce
the stroke lengths in the side areas of the cooler. By this way the transport
speed in that area will be lower and the tendency of the clinker to move along
the sides and the occurrence of hot clinker flows (red river) is considerably
reduced.

The number of movement cycles per minute (number of strokes) is much

lower than at conventional cooler due to the possibility to operate the
cooler with long stroke lengths. As a result there are particularities in the
discharge of the clinker material from the HE module which must be considered
in the scanning of the reference pressure.

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Process, operation and optimization of the ETA Cooler

Variable stroke length

Recuperation zone Cooling zone

Active Controllability of Clinker Bed

Static inlet section Efficient heat recuperation

Chamber Side Aeration Controlled zone cooling

Individual stroke length Flexible clinker retention time

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Process, operation and optimization of the ETA Cooler

Speed of forward and backward stroke

The speed of the forward and backward stroke is controlled by the EMCC,
depending on the transport capacity.

The speed of the backward stroke of a lane is maximal approx. three times
higher than the speed of the forward stroke to ensure that the time for the
working stroke in clinker transport direction is as long as possible.

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Process, operation and optimization of the ETA Cooler

Transport capacity

The transport capacity describes the distance covered by all lanes during a defined
time.

Current transport capacity

Σ operating stroke lengths

Transportcapacity (actualvalue) = [ mm/s ]
Cycletime

Maximally achievable transport capacity

Number of walkinglanes ⋅ max imum operating strokelength

Transportcapacity (max imal ) = [ mm/s]
min ium time per movementcycle

100 % indicates that all lanes are operated at the maximum stroke length and the
shortest time allowed by the hydraulic system.

Transportcapacity (realvalue)
Transportcapacity (%) = ⋅ 100%
Transportcapacity (max imum)

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 Process, operation and optimization of the ETA Cooler

Maximally achievable transport capacity

Preconditions for an example with 4 lanes:

Maximum stroke length during Minimum time per movement

operation* cycle

200 mm 5,0 sec

300 mm 7,5 sec

400 mm 10 sec

480 mm 12 sec

Because all 4 lanes are supposed to cover a defined distance in the same time, the
longest stroke length available is used to determine the minimum time.

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 Process, operation and optimization of the ETA Cooler

Result
4 ⋅ 480mm
Transportcapacity (max imum) = = 160mm / sec
12 sec

Actual value of the transport capacity

Preconditions:

1. stroke length during operation = 150 mm (outer walking

lanes) and 300 mm (inner lanes)

2. time per movement cycle = 18 sec

Result
2 ⋅ 150 + 2 ⋅ 300
Transportcapacity ( realvalue) = = 50mm / sec
18 sec

50mm / sec
Transportcapacity (%) = ⋅ 100% = 31%
160mm / sec

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Process, operation and optimization of the ETA Cooler

Summary of example

1. Only 31 % of the available drive capacity is used.

2. Further 69 % are available by using the available stroke lengths and

increasing the speed of the lanes

3. The limit of the transport capacity of this example is 75 %, if the

number of strokes remains unchanged, ([900 mm / 7,5 sec] /
160mm/sec x 100 %).

4. If the required transport capacity exceeds this value, the control

system automatically adjusts the stroke lengths, to reach the
required higher transport capacity.

During automatic cooler operation with control loop reference pressure or

level radar, the set point for the transport capacity is set by the output of the
respective controller.

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Process, operation and optimization of the ETA Cooler

3 General process correlations – trend curves

Main features of the ETA clinker cooler

1. Cool down the clinker to the lowest possible outlet temperature with a
temperature profile especially defined for the required clinker quality.

2. To heat up the secondary and / or tertiary air for combustion, so that a

high temperature is achieved in the sintering zone of the rotary kiln with
the lowest consumption of fuel for the burner.

The following trend curves are indicating the qualitative influence of the
described process parameters. The quantitative influence and the shape of the
curves are not considered. For simplification, each curve is only indicated
linearly.

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Process, operation and optimization of the ETA Cooler

Clinker throughput – Clinker outlet temperature – Cooling air quantity

Higher clinker throughput

Higher clinker outlet temperature

Constant: transport capacity (cooler in manual operation), cooling air quantity

Clinker outlet temperature

Clinker throughput

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Process, operation and optimization of the ETA Cooler

Clinker throughput – Clinker outlet temperature – Cooling air quantity

Higher cooling air quantity

Lower clinker outlet temperature

Constant: transport capacity (cooler in manual operation), clinker throughput

Clinker outlet temperature

Spec. cooling air quantity

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Process, operation and optimization of the ETA Cooler

Clinker throughput – Clinker outlet temperature – Cooling air quantity

Lower transport capacity

Lower clinker outlet temperature

Constant: clinker throughput, cooling air quantity

Clinker outlet temperature

Transport capacity

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Process, operation and optimization of the ETA Cooler

Clinker throughput – Clinker outlet temperature – Cooling air quantity

Higher clinker throughput

Higher cooling air quantity

Constant: clinker outlet temperature

Air quantity / transport

Cooling air
capacity quantity
Optimum

Number of
strokes

Clinker throughput

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Process, operation and optimization of the ETA Cooler

Spec. cooling air quantity – Secondary air temperature – Cooler efficiency

Lower air supply

Higher secondary air temperature

A lower specific air supply corresponds to a lower air velocity and thus to an increase of the
retention time of the air in the clinker. The heat exchange will improve and a higher
secondary air temperature will be achieved.

The air supply at the HE module must be at least that high that the clinker does not stick
together.

Secondary air temperature

Spec. air supply (1. chamber)

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Process, operation and optimization of the ETA Cooler

Spec. cooling air quantity – Secondary air temperature – Cooler efficiency

Higher secondary air temperature

Higher cooler efficiency

A higher secondary air temperature (higher heat content of the secondary air) increases the
cooler efficiency.

Cooler efficiency

Secondary air temperature

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Process, operation and optimization of the ETA Cooler

Spec. cooling air quantity – Secondary air temperature – Cooler efficiency

Higher cooler efficiency

Lower kiln heat requirement

The higher recuperation allows for a reduction of the fuel in the kiln system. The kiln heat
consumption and operating costs for the kiln system are reduced.

Kiln heat requirement

Cooler efficiency

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Process, operation and optimization of the ETA Cooler

Clinker bed height – Clinker outlet temperature – Cooler efficiency –

Fan pressure – Energy consumption

High clinker bed height

Lower clinker outlet temperature

An increase of the clinker bed height leads to an increase of the retention time of the cooling
air in the clinker bed. This results in an improved heat exchange and thus a lower clinker
outlet temperature. This applies until a limit clinker bed height is reached, where air rushes
occur. The consequence: deterioration of the cooling and higher outlet temperatures.

Clinker outlet temperature

Optimum bed height

Practical

Theoretical

Clinker bed height

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Process, operation and optimization of the ETA Cooler

Clinker bed height – Clinker outlet temperature – Cooler efficiency –

Fan pressure – Energy consumption

Higher clinker bed height

Cooler efficiency
Higher cooler efficiency Optimum bed height
Practical

Increased clinker bed > improved heat Theoretical

exchange
Increased temperature of the
recuperation air > increase in the cooler
efficiency
If the clinker bed height is exceeded, the
heat exchange and the cooler efficiency
Fan pressure Clinker bed height
deteriorate.
Optimum bed height
Theoretical
Higher clinker bed height

Higher fan pressure Practical

Higher clinker bed > increased resistance

for the fan.
Until the limit clinker bed height is reached,
the pressure increases. When the limit
Clinker bed height
clinker bed height is exceeded, the
pressure decreases due to air rushes.
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Process, operation and optimization of the ETA Cooler

Clinker bed height – Clinker outlet temperature – Cooler efficiency –

Fan pressure – Energy consumption

Higher clinker bed height

higher energy requirements

The increase of the clinker bed height and the fan pressure result in an increase
of the specific energy consumption of the fans while the kiln heat requirement
is reduced.

Spec. energy
consumption kiln
Optimum bed height

Energy
consumption
kiln

Electrical energy
consumption

Clinker bed height

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Process, operation and optimization of the ETA Cooler

Cooling air quantity – Transport capacity – Exhaust air quantity –

Exhaust air temperature

Higher cooling air quantity

Higher exhaust air quantity

If more cooling air is used for the cooler the exhaust air quantity is increased.

Exhaust air quantity

spec.cooling air quantity

Picture no. 42
Process, operation and optimization of the ETA Cooler

Cooling air quantity – Transport capacity – Exhaust air quantity –

Exhaust air temperature

Higher transport capacity

Higher exhaust air quantity
Higher clinker outlet temperature

Constant: clinker throughput, cooling air quantity

Exhaust air temperature /

clinker outlet temperature

Transport
capacity
Picture no. 43
Process, operation and optimization of the ETA Cooler

Cooling air quantity – Transport capacity – Exhaust air quantity –

Exhaust air temperature

Lower cooling air quantity

Higher exhaust air temperature

Constant: combustion air quantity, clinker outlet temperature

Exhaust air temperatur

Spec. cooling air quantity

Picture no. 44
Process, operation and optimization of the ETA Cooler

Cooling air quantity – Transport capacity – Exhaust air quantity –

Exhaust air temperature

Higher exhaust air temperature

Higher potential for heat recuperation

An efficient waste heat recuperation requires high exhaust air temperatures. This is mainly
achieved by the intermediate crushing in the stage cooler.

Waste heat
recuperation

Exhaust air
temperatur

Picture no. 45
Process, operation and optimization of the ETA Cooler

Core statements

1. The cooling air supply at the beginning of the cooler mainly influences
the recuperation efficiency of the cooler and clinker quality.

2. By optimization of the bed height the operating costs are reduced.

3. A high transport capacity increases the heat losses of the cooler

(clinker outlet temperature and cooler exhaust air temperature).

Picture no. 46
Process, operation and optimization of the ETA Cooler

4 Differences between ETA Cooler and grate

cooler

To illustrate process and control characteristics of the ETA Cooler, the

differences between the conventional Claudius Peters grate cooler and the
ETA Cooler are described in the following.

Picture no. 47
 Process, operation and optimization of the ETA Cooler

Aeration system

Grate cooler ETA Cooler

DSA (direct side aeration) CSA (controlled side aeration)

Direct aeration of the grate plates in Due to the horizontal movement and
the side area, air supply with slide the simple structure of the ETA
compensators into the moving frame Cooler it is possible to install
beams and from there via the grate longitudinal partition walls. A direct
supports to the grate plates. aeration with slide compensators is
not required.

Effects on process and control

For the air quantity control of the fans the difference between DSA
(direct side aeration) and CSA (controlled side aeration) is not relevant.

Picture no. 48
 Process, operation and optimization of the ETA Cooler

Clinker transport

Grate cooler ETA Cooler

All movable grate plates on one Each lane is driven separately.

grate are moved together by the
grate drive.

Effects on process and control

1. The lane movement can be adjusted according to the hot

clinker zones (tendency of the fine clinker to flow at the sides)

2. The retention time of the clinker can be affected over the width of
the cooler by changing the stroke lengths.

3. An even clinker outlet temperature over the the cooler width can
be realized via the control system. Precondition for this is the
measurement of the clinker temperature over the cooler width,
e.g. with a heat image camera.

Picture no. 49
Process, operation and optimization of the ETA Cooler

Stroke length

Grate cooler ETA Cooler

140 mm max. installed stroke length, 420 mm max. installed stroke length,
120 mm max. operating stroke 400 mm max. operating stroke
length length

Effects on process and control

1. In the ETA Cooler the stroke length can be more than

three times higher.

2. Lower stroke frequency in the ETA Cooler
reduced wear

3. At the ETA Cooler the clinker bed height on the HE module

fluctuates more than in the grate cooler. These fluctuations
caused by the transport system have to be compensated by
the control of the clinker bed height. This can be achieved by
scanning the reference signal (reference pressure or level
radar) always at the same position during the
movement cycle.

Picture no. 50
Process, operation and optimization of the ETA Cooler

Conveying effect (minimum clinker bed height)

Grate cooler ETA Cooler

A minimum clinker bed height of The holding forces in the clinker

approx. 200 mm is possible. layer during backward movement
have the main influence on the
Reason: Small distance between the conveying effect of the ETA
fixed grate rows (many scrapers). Cooler.

With increased clinker bed height

the conveying effect increases.
For a continuous operation the
clinker bed height has to be min.
approx. 600 mm.

The optimum clinker bed height:

ratio clinker bed height / lane
width > 1,2.

Reason: Only one scraper at the

transition from the HE module to the
lanes.

Picture no. 51
Process, operation and optimization of the ETA Cooler

Effects on process and control

1. The conveying effect of the ETA Cooler sets in automatically.

2. The lanes can only be emptied down to a residual bed height of

approx. 200 mm, if the lane operation is maintained for
approx. 8 hours while no clinker is discharged from the kiln.

3. The conveying effect of the ETA Cooler improves with increased

clinker bed height.

4. The ETA Cooler must be operated with a minimum clinker bed of

approx. 600 mm. If at this clinker bed height agglomerates (lumps)
already occur, the formation of such lumps must generally be fought
by means of the air control.

Picture no. 52
Process, operation and optimization of the ETA Cooler

5 Control loops of the ETA Cooler

Survey
A sufficient clinker cooling process is realized by the following control loops:
1. Control of the clinker bed height
(reference pressure of the front cooling air fans or optionally via level radar)
2. Control of the cooling air quantity
3. Gusset monitoring
(Monitoring of the transition area HE module / lanes)
4. Kiln hood pressure control
5. Adjustment of the total cooling air quantity
(Optional, depending on the scope of order)

Objective
The highest possible heat recuperation and the lowest possible clinker outlet
temperature are supposed to be reached by cooperation of the control loops.
At the same time process fluctuations and disturbances are to be kept to a
minimum in order to ensure a stable combustion process.

Picture no. 53
Process, operation and optimization of the ETA Cooler

Control loops
Kiln hood pressure PIRCA Pressure Indication Record Control Alarm

Fan (Chamber) pressure PIRCA Pressure Indication Record Control Alarm

Clinker bed height LIRCA Level Indication Record Control Alarm

Transport capacity SIRC Speed Indication Record Control

Air volume FICA Flow Indication Control Alarm

Measuring loops
Fan (Chamber) pressure PIA Pressure Indication Alarm

Recuperation air temperature TIA Temperature Indication Control

Exhaust air temperatur TIRA Temperature Indication Record Control

Transport lane temperature TIRA Temperature Indication Record Control

Microwave barrier LSA Level Switch Alarm

Picture no. 54
Process, operation and optimization of the ETA Cooler

TI LIR
R C

PIRC M
A

TI
R

PRESSURE
SIR EMC²
LEVEL

TIR TIR
A A

PIRC PIRC PI PI
A A A A
M M M M

FIC FIC FIC FIC

A A A A

Figure 7: Control and measuring loops of the clinker cooler

Picture no. 55
Process, operation and optimization of the ETA Cooler

Control of the clinker bed height

The clinker bed height in the cooler is directly influenced by the transport
capacity.

The transport capacity controls the clinker bed height.

The aim of the clinker bed height control is to produce an even heat exchange
between red hot clinker and cooling air to keep fluctuations of the recuperation
air temperature as low as possible.

Therefore it is necessary to keep the clinker bed height as much as possible

constant.

Deviations between actual clinker bed height and rated height are
compensated by controlling the transport capacity (stroke length / stroke
speed).

Picture no. 56
Process, operation and optimization of the ETA Cooler

At a constant transport capacity (stroke length If the clinker bed height is controlled, the
and stroke speed) fluctuations of the clinker fluctuations of the recuperation air
bed height may cause fluctuations of the temperature can be reduced.
recuperation air temperature.

constant transport capacity variable transport capacity

recuperation air
recuperation air temperature
temperature

Figure 8: Cooler with constant Figure 9: Cooler with control of

transport capacity the clinker bed height

Picture no. 57
Process, operation and optimization of the ETA Cooler
Control correlations and principles
Control deviation

The higher the control deviation, the higher the intervention of the control.
The experience with coolers has shown that a linear correlation between control
deviation (= rated value minus actual value) and control intervention, e.g. in case of
dropping clinker, can lead to adjustment of an excessive or insufficient transport
speed by the control.
If in case of increased deviations between actual value and rated value, a
frequent change of the transport capacity takes place. These fluctuations can
be minimize.
Further it is favorable to adjust a steeper course of the curves of control deviation
and control intervention in case of a positive control deviation than in case of a
negative control deviation in order to avoid that the clinker bed decreases too long
too strongly.

Picture no. 58
Process, operation and optimization of the ETA Cooler

Pressure monitoring of the first fans

In order to avoid that an excessive operating pressure of the cooling air fans in the
front area of the cooler causes an overload of the fans and a reduction of the
cooling air quantity, the operating pressure of these fans is monitored.
If the limit pressure of a fan is exceeded, the transport capacity of the ETA
Cooler is automatically increased, so that the clinker bed height decreases
and the flow resistance of the clinker bed and the operating pressure of the
fan are reduced.

Picture no. 59
Process, operation and optimization of the ETA Cooler

Control via reference pressure

The clinker bed height is controlled via the operating pressure of the cooling air
fans in the front area of the cooler.

By a variable transport capacity the reference pressure is kept constant. There

is a influence in the clinker bed height by different clinker grain sizes.

Precondition for keeping the reference pressure constant is a constant air

quantity of the reference fans.

To avoid that the cooler is overfilled, the set point of the reference pressure has
to be automatically lowered when the air quantity is reduced.

If the pressure of a cooling fan is exceeding a high limit, the transport capacity
of the ETA Cooler is automatically increased, so that the clinker bed height
decreases and the flow resistance of the clinker bed and the operating pressure
of the fan are reduced.

Picture no. 60
 Process, operation and optimization of the ETA Cooler

1,1 2,0 [m/sec]

Figure 10: Reference pressure in correlation with the air load

Picture no. 61
Process, operation and optimization of the ETA Cooler

Control correlations

Increase of the flow resistance in the clinker bed

If the clinker throughput or the share of fine grains is increasing the reference
pressure (actual value) will increase as well.

Reduction of the flow resistance in the clinker bed

If the clinker throughput or the share of coarse grains is decreasing the

reference pressure (actual value) will reduce as well.

Picture no. 62
Process, operation and optimization of the ETA Cooler

Core statements

1. The reference pressure depends on the air quantity of the reference

fans. With increased air quantity, the reference pressure also is
increasing.

2. Therefore in practice the set point of the reference pressure must be

adjusted to the air quantity. This is realized by the automatic pressure
standardization for the reference fans.

Picture no. 63
Process, operation and optimization of the ETA Cooler

Control via measurement of the clinker bed height (CP

Level Radar)

The clinker bed height is measured directly via a radar system. Measurement
takes place directly behind the HE module.
Due to the direct measurement, different clinker grain sizes do not have any
influence in the bed height.

Control correlations

If the actual value of the clinker bed height is lower than the set point, the
transport capacity is automatically reduced.

If the actual value of the clinker bed height exceeds the set point, the
transport capacity is automatically increased.

Picture no. 64
Process, operation and optimization of the ETA Cooler

Requirements on the control accuracy

Control via reference pressure

During trouble-free automatic operation, the actual value of the reference

pressure should not differ more than max. ± 2 mbar from the set point.

Control via measurement of the clinker bed height by

a level radar

During trouble-free automatic operation the actual value of the clinker bed height
should not differ more than max. ± 5 % from the set point.
A deviation of less than ± 2 % during trouble-free automatic operation is
recommended.

Picture no. 65
Process, operation and optimization of the ETA Cooler

Control parameters for the clinker bed height

Two separate controllers are existing.

1. The reference pressure controller.

2. The clinker bed height controller by a level radar

For both controllers the start values of the parameters are the same.

Parameters Symbol Value Unit Remarks:

Gain Kp 1,5 ---

Xp 67 %
Reset time TI 250 Sec

Rate time TD 0 Sec

Filter time for TF 15 Sec

actual value
Dead band DZ 0 %

Picture no. 66
Process, operation and optimization of the ETA Cooler

Operation modes

The normal operation mode of the cooler is the automatic operation.

In the following you will find explanations and requirements for the operation modes

1. automatic
2. manual
3. local

of the hydraulic drive of the lanes.

Picture no. 67
Process, operation and optimization of the ETA Cooler

Hydraulic lane drive in automatic operation

The reference variable for the control of the grate speed is

1. The reference pressure of the fans in the kiln discharge area or

2. The clinker bed height measured by a level radar

For switch-over from hand to automatic and back, each controller should be
provided with a set point correction to allow a smooth switch-over.

The control range is between 10 % and 100 % of the transport capacity. By

shortening the stroke lengths, the control range is reduced.

If the gusset monitoring is activated, the lanes are automatically stopped and
are restarted when the gusset monitoring is deactivated again.

At the EMCC (ETA Motion Control Center) a minimum transport capacity can
be adjusted during automatic operation.

Picture no. 68
Process, operation and optimization of the ETA Cooler

Hydraulic lane drive in manual operation

1. An automatic control of the clinker bed height does not take place
2. The set point for the transport capacity has to be adjusted manually

Hydraulic lane drive in local operation

1. Local operation is only suitable for test or adjustment measures and

for the elimination of malfunctions.

Picture no. 69
Process, operation and optimization of the ETA Cooler

Optimization of clinker bed height control

An optimization of the heat exchange has to be realized mainly via the clinker
bed height.

The secondary air temperature and the clinker outlet temperature have to be
used for determination of the best set point for the clinker bed height
controlled by pressure or level.

Regular inspection and maintenance of the level radar or the pressure

measuring is the precondition for the functioning of the clinker bed height
control.

Picture no. 70
Process, operation and optimization of the ETA Cooler

Measures in case of malfunctions

Failure of the clinker bed height measurement (level radar)

A switch-over to the reference pressure control or manual operation of the

hydraulic lane drive is required.
The average transport capacity of the previous automatic operation should be
selected for manual operation.

Strong clinker bed fluctuations

If the clinker bed height fluctuates strongly for reasons, which are not related
to the process, manual operation with constant transport capacity is
recommended.
The clinker bed height controller and its parameters, the level radar (optional)
and the pressure measurement have to be checked.

Picture no. 71
Process, operation and optimization of the ETA Cooler

Standstill of lanes

1. If there is a failure of one lane only, operation of the cooler can be

continued.

2. If there is a failure of two lanes, operation can be continued only as long

as one of the cases shown in Figure 9 is present. In case of different
combinations, the cooler has to be shut down.

3. In case of failure of more than two lanes, the cooler must be shut down.

Figure 9 gives a survey of the admissible combinations of lane failures for

different ETA Cooler sizes.

Picture no. 72
 Process, operation and optimization of the ETA Cooler

Figure 11: Admissible variants for the failure of two lanes

Picture no. 73
Process, operation and optimization of the ETA Cooler

6 Aeration system
Main functions and objective

The pressure to be built up by the cooling

air fan is composed of

1. The system pressure loss p1

(air ducts, lane and
protective clinker layer)
2. The pressure loss p2 of the
clinker bed

Figure 12: Pressure loss of a fan

Picture no. 74
Process, operation and optimization of the ETA Cooler

Control of the cooling air fans to ensure

1. an even air flow through the clinker layer

2. an even heat exchange between clinker and cooling air

The cooling air fulfils the following functions

1. Cooling of the clinker

2. Recuperation of the clinker heat for the combustion process
3. Protection of the cooler components against thermal overload

Picture no. 75
Process, operation and optimization of the ETA Cooler

Process correlations
Cooling fan characteristic curve

The following correlations apply

1. With increasing of the air quantity the pressure loss of the fan increases.
2. With increasing of the clinker bed height the pressure loss of the fan
increases.
3. With increasing of the fineness of the clinker the pressure loss of the fan
increases.

Requirements
The cooling air quantity has to be kept constant to minimize the fluctuation in the
combustion and clinker cooling process.

Picture no. 76
Process, operation and optimization of the ETA Cooler

Figures 11 and 12 indicates the cooling fan characteristic with speed control

At constant speed of the fan, air quantity Via the speed control of the fan the air
fluctuations occur which are caused by quantity is kept constant.
pressure fluctuations.

Figure 13: Fan characteristic curve Figure 14: Fan characteristic curve
without air quantity control with air quantity control

Picture no. 77
Process, operation and optimization of the ETA Cooler

Flow velocity and specific air supply in the modules

Depending on the clinker throughput the cooling air quantity for each fan has
to be adjusted.

In addition to the total cooling air quantity the flow velocity and the specific air
supply are used as reference.

The flow velocity is the quotient of air quantity and aerated grate surface. The
unit is Am/s or Nm/s.

The specific air supply is the cooling air quantity for a certain area. The unit is
Am³/hm² or Nm³/hm².

Picture no. 78
Process, operation and optimization of the ETA Cooler

Example

Aeration area of the fan 5 m²

Air quantity during operation 20000 Am³/h

Flow velocity 20000 Am ³ 1 h

⋅ ⋅ = 1,11Am / sec
h 5m ² 3600 sec

Spec. air supply 20000 Am ³ 1

⋅ = 4000 Am ³ / hm ²
h 5m ²

For a better comparison the flow velocity is usually converted from operating
condition to normal condition (Nm/sec).

Picture no. 79
Process, operation and optimization of the ETA Cooler

The following relations apply

1. With increasing of the flow velocity (cooling air quantity) the clinker
cooling improves. The clinker outlet temperature is reduced.

2. In case of excessively high flow velocities, cold air rushes (fountains)

occur in the clinker layer. These causes a deterioration of the clinker
cooling and the heat recuperation.

3. With decreasing of the flow velocity (cooling air quantity), the heat
recuperation for the combustion process in the kiln improves. The
retention time of the air in the clinker layer is longer when the air velocity
is lower.

4. During hot commissioning the air distribution (air quantity of the single
fans) must be optimized, in order to ensure a high heat recuperation as
well as a low clinker outlet temperature. The new adjustment of the fans
has to be documented in the data sheet “Basic data aeration system”.

Picture no. 80
Process, operation and optimization of the ETA Cooler

Cooling air quantity of a fan

Vane- as well as speed controlled fans need a minimum air quantity during
operation in order to reach an controllable point on the fan characteristic
curve.

For speed-controlled fans the cooling air quantity can not be reduced to zero,
to avoid overheating of the electric motor.

Independent of the raw meal feed (throughput capacity) the clinker always
enters the cooler with a temperature of approx. > 1400 °C.

If the air quantity at the HE Module is not sufficient, clinker lumps can form at
the surface of the clinker layer.

Attention!

Thermal damages of the HE module grate plates and lanes are always a result
of air losses (failure of a fan, leakages in the air ducts, insufficient air supply,
etc.).

Picture no. 81
Process, operation and optimization of the ETA Cooler

Minimum cooling air quantity of a fan

For the fan / the fans of the HE module, special requirements apply for adjustment
of the minimum air quantity.

Independent of the raw meal feed (throughput capacity) the clinker always enters
the cooler with a temperature of approx. 1400 °C.

The cooling air quantity of the first fan never should be reduced too strongly, not
even during partial load operation, in order to be able to cool the clinker sufficiently
on the one hand and on the other hand to avoid a thermal overload of the grate
plates.

If the air quantity at the HE Module is not sufficient, clinker lumps can form at
the surface of the clinker layer.

The air quantity required for first commissioning is indicated in the data sheet “Basic
data aeration system”. During commissioning all air quantity set points have to be
optimized for the actual operating conditions.

Picture no. 82
Process, operation and optimization of the ETA Cooler
Control with frequency converter

Keeping the cooling air volume constant via the fan speed instead of the
damper allows a better partial load efficiency and reduces the sound emission
at reduced speed.
For this reason fans with speed control should be preferred in cases where large air
quantity reserves are available, i.e. where operation is expected to be in the lower
partial-load range.
The cooling air volume cannot be reduced to 0 %, since the speed of the
electric motor must not drop below a minimum for cooling.
Fans for speed control should not have a critical speed in the working range. If
nevertheless critical speeds occur during operation, it must be considered whether
the range is critical for operation or whether the fan has to be balanced anew.

Picture no. 83
 Process, operation and optimization of the ETA Cooler

Control of the total cooling air quantity

As an option it is possible to
Cooling adjust the cooling air quantities
air of all fans automatically,
100% depending on the raw meal
input.

This is realized by means of a

Fan curve joint set point device.
Cooling air volume

Min. ( setpoint curve )

cooling .
air
aprox. 30
%

30% Setpoint
operation
0% Start min 100%
up operation

Setpoint : raw meal feed

Figure 15: Adjustment of the total cooling air volume

Picture no. 84
Process, operation and optimization of the ETA Cooler

Requirements of the accuracy

During automatic operation the actual value of the air quantity of a fan should
differ maximally ± 2,5 % from the rated value. In exceptional cases a deviation
from the set point of up to max. ± 5 % can be accepted.

For the reference fans of the clinker bed height control the actual value of the
air quantity may deviate by maximally ± 1 %.

An air quantity fluctuation of e.g. ± 5 % leads to a pressure dead band of ± 10

% where the reference pressure does not work accurately.

Picture no. 85
Process, operation and optimization of the ETA Cooler

Control parameters for the cooling air quantity

Start up parameters

Parameters Symbol Value Unit Remarks:

Gain Kp 0,3 ---

Xp 333 %
Reset time TI 15 Sec

Rate time TD 0 Sec

Filter time for TF 30 Sec

actual value
Dead band DZ 0 %

Picture no. 86
Process, operation and optimization of the ETA Cooler

Operation modes of the aeration system

In the following you will find explanations and requirements for the operation modes

1. automatic
2. manual
3. local

operation of the aeration system.

Picture no. 87
Process, operation and optimization of the ETA Cooler

Cooling fans in automatic operation

All fans are connected to a joint set point device.

The set point for the cooling air has to be adjusted to the raw meal feed at each
fan controller..

The installation of a joint set point device is optional.

The actuating device (damper, frequency converter for speed control) is

designed in such a manner that the cooling air quantity can be kept constant
within a tolerance of ±2,5 %.

The operating air quantity is monitored by an alarm “negative control

deviation”.

Picture no. 88
Process, operation and optimization of the ETA Cooler

Cooling fans in manual operation

If the reference fan is operated in manual mode, the reference for the speed
control is lost.

During manual operation, no air quantity control takes place when the clinker
bed height on the lanes is changed. This means, if the clinker bed height
increases and thus the pressure of the fan, too, the air quantity decreases in
accordance with the fan curve.

Cooling fans in local operation

Local operation is only used for test and adjustment procedures and for the
elimination of malfunctions.

Picture no. 89
Process, operation and optimization of the ETA Cooler

Optimization of the cooling air quantity control

For trouble free functioning of the air quantity control the following
maintenance work and inspections are required.

1. Remove cloggings at the measuring bores of the measuring nozzle of

the fan inlet nozzle

2. Remove water accumulations in the measuring line

3. Check the adjustment of the flow transmitters

Measures in case of malfunctions

Manual operation of the fan (air quantity control loops) with constant speed is
necessary. The average speed of the previous automatic operation should be
used.

Picture no. 90
 Process, operation and optimization of the ETA Cooler

Figure 16: Assembly of measuring point for cooling air flow and fan pressure
transmitter with test connection

Picture no. 91
Process, operation and optimization of the ETA Cooler

7 Gusset monitoring

Function and objectives

During forward movement of the lanes, a gusset may form in the clinker bed
right behind the HE module.

This emptying of the front area of the lanes must be avoided in order to reduce
the thermal load on the lanes in this zone.

Gusset monitoring is realized by means of a pressure measurement in the rear

aeration fields of the HE module and the central area of the first start module
(see grey-shaded fields in Figure 20)

Picture no. 92
 Process, operation and optimization of the ETA Cooler

Figure 17: Section of an aeration scheme (cooler with 4 WL) /

Gusset monitoring area

Picture no. 93
Process, operation and optimization of the ETA Cooler

Basic principle of the gusset monitoring via the

cooling fan pressure

If the actual value of the fan pressure, measured in the rear aeration fields of
the HE modules or in the center of the start module is below a defined lower
limit value, the gusset monitoring is activated. All lanes are stopped in their
current operating position.

When a defined upper limit value of the pressure is reached, the gusset
monitoring is deactivated and the lane movement is restarted.

Picture no. 94
Process, operation and optimization of the ETA Cooler

8 Kiln hood pressure control

Function and objective
The exhaust air fan controls the kiln hood pressure. An even heat transfer / an
even hot air flow from the cooler into the kiln is ensured at a kiln head
pressure of approx. -0,1 mbar to -0,3 mbar.

PIRCA M

Figure 18: Kiln head pressure control

Picture no. 95
Process, operation and optimization of the ETA Cooler

Basic principle of kiln hood pressure control

Keeping the kiln hood pressure constant by use of the exhaust air fan

If the kiln hood pressure becomes more positive, the hot air accumulates in
the cooler upper part. The zero point in the cooler upper part moves into the
direction of the cooler inlet (kiln). The air quantity of the exhaust air fan is then
automatically increased to reduce the kiln hood pressure down to the set point

If the kiln head pressure drops, the hot air in the cooler upper part is
insufficient. The zero point in the cooler upper part moves into the direction of
the cooler outlet (clinker crusher). The air quantity of the exhaust air fan is
then automatically reduced to increase the kiln hood pressure to the set point.

Picture no. 96
Process, operation and optimization of the ETA Cooler

Process correlations

Via the kiln hood pressure control, a balance of the hot air streams in the
cooler upper part is provided.

The recuperation air is taken by the pre heater fan.

The remaining cooling air is lead off as exhaust air.
A zero point is established inside the cooler.

The negative pressure at the cooler exhaust air duct is approximately the same
as at the kiln hood.

Picture no. 97
Process, operation and optimization of the ETA Cooler

The negative pressure at the kiln hood has to be in the range of -0.1 to
-0.3 mbar.

If the pressure at the kiln head becomes more negative, false air entering at
the kiln sealing is increasing. False air is cold air which enters the kiln or the
cooler from environment. The false air has to be heated up by additional fuel.
Due to an excessively high negative pressure at the kiln hood, heat losses
occur.

A high negative pressure at the kiln hood is often accompanied by high flow
velocities of the hot air which leads to an increase of the dust quantities in the
recuperation air. Here also increased heat losses occur.

Picture no. 98
Process, operation and optimization of the ETA Cooler

Requirements on the control accuracy

During automatic operation the actual value of the kiln hood pressure should
deviate from the set point only by max. ± 0,1 mbar.

Please note:
In case of obstructions in the kiln operation a short-time strong deviation from
the set point is possible.

Picture no. 99
Process, operation and optimization of the ETA Cooler

Operation modes of the kiln hood pressure control

In the following you will find explanations and requirements for the operation modes

1. automatic
2. manual
3. local operation

Picture no. 100

Process, operation and optimization of the ETA Cooler

Kiln hood pressure controller in automatic mode

The reference variable for the control of the kiln hood pressure is the cooler
exhaust air quantity.

The control range is between + 1 mbar and – 1 mbar.

In case the adjustable value for the kiln hood pressure is exceed or not
reached, an alarm is activated.

Kiln hood pressure controller in manual mode

If the kiln hood pressure is operated manually, no air quantity control takes
place by the exhaust air fan when the kiln hood pressure is changed.

Kiln hood pressure controller in local mode

Local operation is only used for test and adjustment procedures and for the
elimination of malfunctions.

Picture no. 101

 Process, operation and optimization of the ETA Cooler

Optimization of the kiln hood pressure

For trouble free functioning of the air quantity control the following
maintenance work and inspection is required.

1. Remove cloggings at the measuring points

Usually, the kiln hood pressure is measured via three measuring points,
connected by a ring main. The measuring points on the top of the kiln hood
general have a tendency to clog. A regular mechanical cleaning is necessary
sometime even at shift intervals.

2. Remove water accumulations in the measuring line

3. Check the adjustment of the pressure transmitters regularly

Picture no. 102

Process, operation and optimization of the ETA Cooler

Control parameters for the kiln hood pressure control

Start up parameters

Parameters Symbol Value Unit Remarks

Gain Kp 0,8 ---

Xp 125 %
Reset time TI 15 Sec

Derivative time TD 0 Sec

Filter time for TF 5 Sec

actual value
Dead band DZ 0 %

Picture no. 103

Process, operation and optimization of the ETA Cooler

Measures in case of malfunction

Manual operation of the exhaust air fan at constant speed is required.

The average speed of the previous automatic operation should be chosen.

Picture no. 104

Process, operation and optimization of the ETA Cooler

9 Adjustment of the total cooling air

Air distribution in the cooler

The cooling air distribution in the cooler has to be adjusted according to the
cooling-down curve of the clinker.

The cooling efficiency of the air is more effective at the inlet of the cooler than
at the end of the cooler.

The heat exchange between clinker and air is mainly determined by the air
quantity of the first cooling air fans.

To cool down the clinker from approx. > 1400°C to approx. 100°C, a certain
total cooling air quantity is required, depending on the raw meal feeding.

If you divide the sum of the total cooling air quantity by the produced clinker quantity
you will obtain the specific cooling air quantity. The specific cooling air quantity is
indicated in Nm³/kgclinker.

Picture no. 105

Process, operation and optimization of the ETA Cooler

By increasing the specific cooling air quantity the clinker outlet temperature
decreases but the energy consumption of the plant increases.

Usually the corresponding set points for the cooling air quantity have to be
entered manually.

If a total air quantity controller or a table with the corresponding set points is
stored in the control system, adjustment of the cooling air quantities,
depending on the raw meal feed, takes place automatically.

Picture no. 106

Process, operation and optimization of the ETA Cooler

Figure 19: Exemplary clinker cooling-down curve

Picture no. 107

Process, operation and optimization of the ETA Cooler

10 Start sequence of the cooler aggregates

Start sequence of the cooler aggregates in
combination with the kiln

Operation of the following cooler aggregates must be ensured in the indicated

sequence before start of the raw meal feeding.

Picture no. 108

Process, operation and optimization of the ETA Cooler
No. Aggregate Remarks on start

1 Oil conditioning of lane drive Observe preliminary time for

heating up of the oil
2 Fans in the discharge area As required for heating-up of the
kiln, ascending in material flow
direction, if necessary form groups
3 Exhaust air fan with kiln hood pressure
control
4 Fans of the subsequent chamber Ascending in material flow direction

5 Clinker crusher Observe instructions on the start-up

of the crusher!

6 Hydraulic pumps for the lane drives The start-up conditions of the pump
must be observed (e.g. min. oil
temperature).
7 Walking lane drives Important preconditions:
· clinker transport in operation
· clinker crusher in operation
· cooling air fans in operation

After the lane drives have been started, the release for kiln operation is given.
During start-up operation, the kiln operation can also be released manually,
even if the lanes are not in operation.

Picture no. 109

Process, operation and optimization of the ETA Cooler

11 Alarms
Objective

Alarm messages are used for process control.

For recognition and localization of malfunctions, in order to be able to take
counteraction as soon as possible and to avoid consequential damages.

In the following you will find the alarm messages relevant for the cooling process.

Picture no. 110

Process, operation and optimization of the ETA Cooler
No. Function Alarm Possible cause Remedy
status

1 Cooling air L Drive has failed Check the fan drive and
quantity of the Suction opening is the suction opening
fans clogged
Measuring nozzle is
clogged

2 Kiln hood H Exhaust air fan in

pressure manual mode
Failure of the
preheater fan

Exhaust air fan in

manual mode
3 Pressure of the H Clinker bed too high Reduce clinker bed height
fans and / or cooling air and / or reduce cooling air
quantity too high quantity

L Leakage in the air Check the fans and the air

duct ducts
Failure of a fan

Picture no. 111

Process, operation and optimization of the ETA Cooler
No. Function Alarm Possible cause Remedy
status

4 Clinker bed height H Standstill of lanes Reduce or stop the raw

in the cooler meal input if elimination of
the failure takes longer

L Transport capacity too In case of control via the

high reference pressure this
means that the set point
for the reference pressure
has to be increased. This
will lead to a reduction of
the transport capacity.
In case of control via the
CP Level Radar, the set
point for the clinker bed
height must be increased.
Observe available fan
pressure.

5 Walking lane H Clinker bed height too In case of short

temperature low temperature peaks
Cooling air quantity (contact heat from large
too low clinker lumps) no action is
Contact heat from required.
large clinker lumps Check clinker bed height
control, air quantity control
and set points.

Picture no. 112

Process, operation and optimization of the ETA Cooler
No. Function Alarm Possible cause Remedy
status

6 Temperature in H Cooling air quantity of Check fan

module 1 fans too low Check clinker bed height
Clinker bed height on control
lanes too low Check functioning of
gusset monitoring

7 Compressed air L Compressed air Re-establish compressed

supply of supply is interrupted air supply.
secondary air
measurement

8 Monitoring of
hydraulic lane
drives
L Leakage at hydraulic Remove leakage and refill
Oil level in the pipelines, in the oil, if required.
tank hydraulic aggregate or
at the cylinders

Oil temperature H Failure of oil

conditioning Check the oil conditioning,
High ambient among other things, of the
temperature temperature switching
point

Picture no. 113

Process, operation and optimization of the ETA Cooler

No. Function Alarm Possible cause Remedy

status

9 Exhaust air H Poor clinker cooling in Open fresh air flap for
temperature the recuperation zone protection of the filter and /
Total cooling air or activate the water
quantity too low injection
Increase the total cooling
air quantity
Water injection defective
Check measuring value for
correct information (field
measurement / local high
value, may not be
representative).
10 Speed controller L Crusher drive stands Determine and eliminate
of clinker crusher still the cause for the standstill
of the crusher.

11 Circulation air H Air/Air heat exchanger Intensify the cooling of the

temperature defective or wrongly circulation air (open fresh
adjusted air flap or connect further
stages of the air/air heat
exchanger).

Picture no. 114

Process, operation and optimization of the ETA Cooler

12 Interlocking of the cooler

Objective

In case of a malfunction or a failure of a drive, the process interlocking

ensures that no consequential damage will be caused.

Furthermore it is insured that the plant components can be restarted after a

stop or after elimination of the malfunction.

Picture no. 115

Process, operation and optimization of the ETA Cooler

Start interlocking

The lanes can only be started after all other cooler aggregates have been put
into operation.

After the lanes have been started, release for kiln operation is given.

During start-up operation the kiln operation can also be released manually,
even if the lanes are not moving.

Picture no. 116

Process, operation and optimization of the ETA Cooler

Operation interlocking
Without internal protection interlocking of the aggregates.

No. Release for Operating conditions, which must be fulfilled

1 Hydraulic drive of The cooling air fans must be in operation

the lanes No fan of the group* must stand still for more than 3
minutes and the air quantity must not drop below the
minimum quantity for more than 3 minutes
No two fans must stand still at the same time
The clinker crusher must be in operation.
The clinker transport behind the cooler must be in
operation

2 Clinker crusher The clinker transport behind the cooler must be in

operation

3 Kiln Exhaust air fan and kiln hood pressure control must not
be out of operation for more than 3 minutes.
The hydraulic pumps of all lane drives must be in
operation (max. standstill time 5 min.)

Picture no. 117

Process, operation and optimization of the ETA Cooler

The specified times are exemplary for group 1.

The cooling air fans are usually divided into groups.

Different times apply for the different groups.

The further back the cooling air fans are arranged, the longer the switch-off times.
For instance, the following applies:

Group 1 HE module with 3 min

Group 2 module 1 and 2 with 3 min
Group 3 CSA aeration with 5 min
Group 4 module 3 and 4 with 10 min
Group 5 starting at module 5 with 20 min

Picture no. 118

Process, operation and optimization of the ETA Cooler

13 Check list for commissioning

The below mentioned groups have to be checked for the following functions during
commissioning:

Mechanical functions
Electrical functions

Functioning in the different operation modes

1. automatic (depending on the process interlocking and alarms)

2. manual
3. local

Picture no. 119

Process, operation and optimization of the ETA Cooler

Groups

- Walking lane drive

- Clinker crusher
- Aeration system
- Measuring and control loops
- Checking for control behavior, indication, registration and alarm
evaluation
- Control loop cooling air quantity individually and together with set
point device

Picture no. 120

 Process, operation and optimization of the ETA Cooler

Groups

- Measuring loop fan pressure

- Measuring loop chamber pressure
- Measuring loop lane temperature
- Measuring loop chamber temperature
- Measuring loop secondary air temperature
- Control loop kiln hood pressure
- Measuring loop exhaust air temperature
- Gas temperature measuring device secondary air / tertiary air
temperature
- Air blasters for HE module
- Cooler water injection (if existing)

Picture no. 121

Process, operation and optimization of the ETA Cooler

14 Operating conditions
Required work before start of the cooler

Coarse grained clinker has to be put at the HE module and in the pockets of
the lanes have also to be filled with pebbles (16-32mm) or coarse clinker
(grain size 30 mm).

This is required for the thermal and mechanical protection of the grate plates
at the HE module and the lanes during start-up of the kiln.

Further, clogging of the aeration slots in the grate plates and the lanes can be
minimized in case liquid material, such as e.g. oil from the main burner,
enters the cooler

Picture no. 122

 Process, operation and optimization of the ETA Cooler

Figure 20: Coarse grained clinker for thermal and mechanical protection

Picture no. 123

Process, operation and optimization of the ETA Cooler

Heating up of the kiln

If required a number of cooling air fans have to be operated during heat up

procedure for sufficient combustion air.

Start up operation

The operation from raw meal feed to constant kiln operation.

During start-up operation the fans and the lanes are operated in automatic
mode.

The air quantities are adjusted in accordance with “Data sheet aeration
system”, depending on the raw meal feed.

Picture no. 124

Process, operation and optimization of the ETA Cooler

Continuous operation

The operation of the cooler at constant kiln operation.

During continuous operation the fans and the lanes are operated in automatic
mode.

The air quantities are adjusted in accordance with “Data sheet aeration
system”, depending on the raw meal feed.

The clinker bed height control will either be realized by the reference
pressure or clinker bed height measurement (level radar).
.

Shut down operation

Shut-down operation of the cooler starts after the raw meal feeding has been
stopped.

For protection of the HE module and the lanes, the cooling air fans have to be
operated for at least one more hour with minimum air quantity

Picture no. 125

Process, operation and optimization of the ETA Cooler

15 Information on the optimization of the cooler

operation
For improvement of the process operation of the cooler, the actual conditions
and the available reserves of e.g. air quantity, fan pressure, transport capacity
have to be considered.

No. Observation Reason Possible Remedial measures

consequences

1 Air rushes / 1 Air supply too Deterioration of 1 Check the air supply
clinker high the clinker
fountains in cooling
the cooler 2 Uneven clinker 2 Adjust the stroke
layer on the lengths / speed of the
lanes single lanes

3 Clinker bed 3 After check of air

height not supply, optimize
adjusted to the clinker bed height
air supply

Picture no. 126

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

2 Low 1 Air supply in Fuel Check the air supply

recuperation the consumption of
efficiency, recuperation kiln system
secondary zone too high increases
air
temperature
too low
2 Air rushes

3 High quantity of Fuel Locate and close

false air in the consumption false air openings,
kiln hood increases i.e.:
Close doors and
inspection window at
the kiln hood.
Minimize gap of the
kiln hood sealing.
Adjustment of set
point kiln hood
pressure (target
value -0,1 to -0,3
mbar )

Picture no. 127

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

3 Transport Set point High clinker Increase set point

capacity too (reference outlet (reference pressure) for
high pressure) too low temperature, grate speed
higher thermal
load on the
lanes

4 Transport Wrong adjustment Kiln fluctuations Check the control

capacity of the controller parameters for the control
fluctuation parameters for the of the lanes
high control

Picture no. 128

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

5 Clinker outlet 1 Spec. air Increased 1 Check air supply

temperature quantity too low temperature
too high load of clinker
transport,
clinker silo and
2 Insufficient cement mill 2 Adjust air supply of
cooling of the CSA-aeration, adjust
fine clinker flows stroke lengths of
at the outer outer lanes
lanes (red river)

3 High share of 3 No influencing

coarse grains in possibility via the
the clinker cooler if the crusher
is at the cooler end

Picture no. 129

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

5 Clinker outlet 4 Clinker Increased 4.1 Reduce clinker

temperature agglomerates temperature inlet temperature
too high (lump formation load of clinker by changing the
in the kiln transport, flame
discharge area) clinker silo and
cement mill 4.2 Increase the air
supply in the kiln
discharge area

4.3 Check raw meal

composition /
possible
measures to
increase the
silicate module
5 Clinker bed 5 Increase set point
height too low (reference
(transport pressure or rated
capacity too bed height)
high)

Picture no. 130

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

6 Walking lane 1 Air losses Increased 1 Check fans,

temperature due to fan thermal load on air ducts and cooler
too high failure, the lanes lower part for
leakages in leakages. Check air
the air ducts supply.
or air
chambers or
insufficient
air supply

2 Clinker bed 2 Increase set point

height too (reference pressure
low (transport or rated bed height)
capacity too
high)

Picture no. 131

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

7 Overpressure 1 High pressure Fluctuations in 1.1 Look for and

at kiln hood losses on the whole kiln eliminate the cause
crude gas or system of the increased
exhaust air pressure loss
side, e.g. by
clogging 1.2 Control of exhaust
air too slow

1.3 Exhaust air fan

operates under full
load (no control
reserve)

2 Leakage in 2 Remove leakages

the exhaust
air ducts or
the exhaust
air filter

Picture no. 132

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

8 Negative Set point for kiln High false air Check set point; target
pressure in hood pressure too quantity via the value: -0,1 to -0,3 mbar
the kiln hood low kiln hood
too high sealing (high
fuel
consumption)

9 Chamber Leakage in the Air losses cause Remove leakages

pressure in side walls or the thermal
the modules partition walls of overload on the
too low the cooler lower lanes
part

Picture no. 133

Process, operation and optimization of the ETA Cooler

No. Observation Reason Possible Remedial measures

consequences

10 Formation of 1 High clinker Obstructs the 1 Extend pre-cooling

snowman in inlet kiln discharge; zone in the kiln by
the cooler temperature clinker changing the flame
inlet area distribution is
influenced
2 Air supply in 2 Check fans and air
kiln discharge supply
area too low,
e.g. fan failure

3 High melting 3 Check raw meal

phase share composition / check
possible measures
to increase the
silicate module

4 High ash 4 Check combustible

content in the composition and
fuel (e.g. in compensate, if
case of coal necessary, by raw
combustion) meal composition

Picture no. 134

Process, operation and optimization of the ETA Cooler

Air blasters

If the formation of snowman is not prevented by the above measures or a

combination of these measures, air blasters have to be used more frequently
to destroy such agglomerates.

In new coolers additional nozzles without air blasters will be installed.

Depending on the actual conditions in order to be prepared for possible
agglomerates.
If nozzles without air blasters exist, these can be equipped with additional air
blasters or the distribution of existing air blasters can be adjusted / optimized.

During hot commissioning the cycle times have to be adjusted according to

the process condition.

The air blasters have to be divided into groups.

Picture no. 135

 Process, operation and optimization of the ETA Cooler

Group 1

Group 2

Group 3

Figure 21: Example for partitioning of air blasters into groups with timer
Picture no. 136
 Process, operation and optimization of the ETA Cooler

Group 2

Group 3

Figure 22: Example for partitioning of air blasters into groups

Picture no. 137
Process, operation and optimization of the ETA Cooler
Information on the optimization of the cooler operation
Important information:

If the formation of snowman is not prevented by the above measures or a

combination of these measures, air blasters have to be used to destroy such
agglomerates.

In plants without air blasters, such blasters have to be retrofitted.

In plants with air blasters, the time cycles and the operating pressure must be
checked.

In new coolers Claudius Peters will install additional nozzles without air blasters.
Depending on the actual conditions in order to be prepared for possible
agglomerates.
If nozzles exist without air blasters, these can be equipped with additional air
blasters or the distribution of existing air blasters can be adjusted / optimized.

Picture no. 138