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Development

Development of individual actions for clinker cooler optimization and upgrades to reduce operation costs. Project support from assessment to realization (integration)

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Training & Coaching

Training and coaching of plant personnel. Our scope of support for coaching of operators, process, production and maintenance engineers will be adjusted individually.

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Site support

Site support for erection supervision, commissioning, optimization and trouble shooting. Improvement of cooler instrumentation and cooler visualization

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Benchmarking & Certificates

Individual solutions are developed by using benchmarking and technology comparison. Costa and benefits are shown transparently.

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Improvement requires change!

Optimization of clinker coolers is a development process. To achieve the desired results, actual principles and procedures have to be questioned and have to be adapted, if required. Thus, elimination of bottlenecks is in focus.

First step is the evaluation of the existing structure and operation of the clinker cooler.

Auf Basis von Werksinformationen wird ein A-Level Assessment (Fernbegutachtung) durchgeführt, um Optimierungs- und Umbauvorschläge zu erarbeiten.

An A-level assessment (desk study) will be performed based on plant information to generate proposals for optimization and upgrades.

A verification of the results at plant site i soften required (B-level assessment). The scope of delivery will be defined for supplier inquiries. Our support service includes all steps from supplier offer evaluation to process integration.

Training and coaching of plant personnel

Basic clinker cooler training (4 hours)

• Structure and process of grate coolers

• Cooler operation basics

• Cooler maintenance basics

• Evaluation criteria

Advanced clinker cooler training (2 days)

• Air distribution

• Clinker bed height and grate speed

• Cooler instrumentation and control

• Measures for cooler optimization

Coaching

Clinker cooler optimization is realized by changes. New or adapted procedures for maintenance and operation have to be implemented and used. It could be easier to switch back to old behaviors. Thus, the optimization target might be not achieved or just partly achieved. External coaching may facilitate the follow-up of change implementation. Our scope of support for coaching of operators, process, production and maintenance engineers will be adjusted individually.

Site support

Site support for erection supervision, commissioning, optimization and trouble shooting

During kiln shut-down:

• Cooler inspection

• Optimization of chamber sealing

• Gap minimization on grate line

• Empty grate pressure measurements of fans and hydraulic grate drive

• Erection supervision

During kiln operation:

• Optimization of air distribution and air flow control

• Optimization of clinker bed height and grate speed control

• Improvement of process interlocks

• Heat balance

• Commissioning supervision

Any time:

• Improvement of cooler instrumentation and cooler visualization

• Documentation “As built” and “as operated”

• Training and coaching of plant personnel

Benchmarking & certificates for clinker coolers

Benchmarking is used for performance evaluation of clinker coolers. Actual figure are compared with reference figures to identify the potential of optimization and modernization of the clinker cooler.

Design characteristics are:

• Grate area load

• Grate width load

• Area load of the cooler inlet section

• Empty grate pressure factor of the aeration system

Operation characteristics are:

• Cooler efficiency (actual and normalized)

• Cooling efficiency and clinker exit temperature

• Heat transfer coefficient

• Clinker bed height

• Specific cooling air volume

Cost related characteristics are:

• Specific kiln heat consumption (fuel costs)

• Maintenance costs

• Availability (down-time)

Individual solutions are developed by using benchmarking and technology comparison. Costa and benefits are shown transparently.

Clinker coolers are my passion

HMCCC supports you with your clinker cooler.
Our expertise is optimization, upgrade, project planning, training, coaching, benchmarking, site support and trouble-shooting of grate coolers in cement industry.

Hartmut Meyer

Clinker Cooler Consulting

Clinker coolers are my passion

HMCCC supports you with your clinker cooler.
Our expertise is optimization, upgrade, project planning, training, coaching, benchmarking, site support and trouble-shooting of grate coolers in cement industry.

Hartmut Meyer
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Background:

• Since 27 years working in cement industry

-15 years in R&D of clinker coolers

-2 years in sales

-10 years clinker cooler consulting

• Detail knowledge of design, process and automation of all types of grate coolers

• Master degree in systematic design and product development


Goals:

• Increased cooler availability and reliability

• Operation cost reduction by optimization and upgrade of clinker coolers

• Stabilization of kiln operation by optimized cooler control

• Simplification of design and process


Approach:

• Holistic view on design, process and automation

• Training and coaching: Helping plants help themselves

• Investigating current principles and procedures

• Improvement needs change


Motivation:

• Cooperation with plant personnel

• Qualification (training and coaching)

• High heat recuperation

• Reliability

• Operation cost reduction

Downloads

A-Level Assessment

  • Scope of supply
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A-Level Assessment

  • Required plant information
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B-Level Assessment

  • Scope of supply
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Project support

  • Scope of supply
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HM CCC Callback-Service

Do you have additional questions or do you need more information?
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Cooler technology

Main target is high heat recuperation from the clinker cooler to minimize fuel consumption for the kiln system.

For this, two steps are required essentially.

1.Clinker fluidization on the static inlet section

The clinker entering the cooler has a portion of liquid phase, thus formation of agglomerates may occur in the cooler, if the surface of the clinker particles is not cooled sufficiently. Therefore, liquid phase must be frozen on the static cooler inlet section. For this, sufficient cooling air needs to be avaiable on the static inlet section.

2.Low vertical mixing of the clinker in the movable area of the cooling grate

To achieve high secondary and tertiary air temperatures a high temperature gradient over the clinker bed height is required in order to heat up the cooling air evenly. Pre-condition is low vertical mixing of the clinker. Furthermore, operation with high clinker bed is required to increase heat recuperation.

Clinker preparation

1

Gap minimization

2

Clinker bed height

3

Process fluctuation

4

Good clinker preparation and clinker distribution on the static cooler inlet section

The required cooling air volume to freeze the liquid phase depends on the size of the static inlet and the amount of liquid phase in the clinker. Sufficient air flow and fan pressure have to be installed.

Fan reserve are required in order to avoid operation at fan limits. Horse shoe layout has significant impact on clinker distribution and segregation effects like red rivers.

Gap minimization

Small gaps on the moving cooling grate and in the air chambers are required to minimize clinker fall through and air losses.

Gap minimization has direct impact on availability and reliability of the clinker cooler.

Clinker bed height maximization

Grate coolers operate with the crossflow heat exchange principle.

Thus, height of the clinker bed in the movable grate area is very important.

Minimization of process fluctuation

Due to coating formation and coating release kiln discharge is not constant. To minimize process fluctuation automatic control of grate speed

and cooling air flow is required. Under-filling and over-filling on the grate must be avoided.

Clients

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If you have additional questions, or need more information,
please feel free to contact us directly.

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More info

Address

HM CCC
Schulhausstrasse 22,
CH – 5116,
Schinznach Bad,
Switzerland

Email

service [at] hmeyerccc [punkt] com

Phone

+ 41 796 590 775

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Privacy policy and terms

Address:

Hartmut Meyer Clinker Cooler Consulting
Schulhausstrasse 22,
Schinznach Bad,
CH – 5116, Switzerland

DIRECTOR:

Hartmut Meyer
Dipl. Ing.
Phone: + 41 796 590 775

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