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INFINITY FOR CEMENT EQUIPMENT ic

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Grate Cooler
8 Comments / key Equipment Working Principles , types , Daily maintenance, Kiln and Cooler / By admin

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Contents [hide]

1 Grate Cooler
2 1. Introduction
3 2. Types of Grate Coolers
3.1 2.1 In the traveling Grate type
3.2 2.2 Reciprocating Grate cooler
3.2.1 2.2.1 Grate line Configuration
3.2.2 2.2.2. Mechanical Features:
3.2.2.1 A. Grate Plates
3.2.2.2 B. Grate plate support
3.2.2.3 C. Moving frame:
3.2.2.4 D. Air compartments & flap valves:
3.2.3 2.2.3. Grate cooler operation and control
4 3- Clinker Crusher
4.1 3.2. Grizzlies
4.2 3.3. Roller Crusher
5 4. Problems of standard cooler
6 5. Developments Related to Grate Cooler
7 6. Design features of modern grate cooler:
8 7. Grate Cooler Retrofit
9 8. Maintenance on Grate coolers
9.0.1 Related

Grate Cooler
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Grate Cooler

1. Introduction

Clinker Cooling is an Important phase in clinker production

Clinker Cooler is exposed to extremely difficult operating-conditions with a highly abrasive and hot
material.
The Cooling Rate of clinker at elevated temp. has direct impact on cement strength(fig.1).
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cooling and grindability of clinker

(Fig.1)

Four types of clinker coolers were developed the earliest was the shaft cooler then the rotary cooler and
satellite and finally the grate type cooler
Of these types the discussion will be focused on the grate type cooler and the modifications carried out
including the employment of air beam technology and reaching the up to date cooler innovation namely
SF cross-bar cooler

So the discussion will be categorized into three parts as follows:-

Conventional reciprocating grate cooler

Modified air beam cooler (Coolax-cooler)
Cross-bar (SF) cooler

2. Types of Grate Coolers

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The grate type cooler is the most suitable cooler for pre-calciner kiln and for kilns with a high outputs

Nowadays grate cooler are designed for large kiln capacities up to 10000 t/d

It’s based on cross-current cooling air.

The grate coolers can be divided into two main types:-

1. Traveling grate cooler

2. Reciprocating grate cooler

2.1 In the traveling Grate type

A Continuous loop of grate segments transports the material from the feed end of the cooler to the
discharge end and then returns to the feed end to receive a new load of material
The material is transported in bulk without any (individual particle motion)
This type of material transport greatly reduces the heat transfer efficiency

grate cooler f

Carrying a fixed bed of material on a traveling grate without benefit of individual particle movement
leads to (rat-holing).
In this phenomenon a large quality of air will blow through a small area of low resistance while the
surrounding grate area receives little or no air flow

2.2 Reciprocating Grate cooler

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air and temperature conditions in a grate cooler

It have been used for years as an effective means for clinker cooling
The basic concept of the grate cooler is quite simple
 Hot material enters the cooler and travels across a series of grate plates cl
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These grate plates have holes in them to allow the passage of cooling air k
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Pressurization fans supply air to compartments beneath the grate plates
As the material passes across the grates, this air is forced up through the grate plate and through the
bed of hot clinker producing the desired cooling effect
The reciprocating grate action provides particle turnover to expose each clinker surface to contact with
air current
A comparison made between various types of coolers, claimed generally 5% more heat recuperation of
the reciprocating cooler versus the traveling grate cooler
The higher efficiency was explained by the tumbling action of the clinker as it travel across the stepped
grate plates

2.2.1 Grate line Configuration

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grate line configuration

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grate cooler types

I- 15o Cooler :

Old cooler had a grate line with 15o slope this slope experienced material fluidization and run off the grate,
preventing build up a deep clinker bed

II- 10o cooler :

– It was obtained by decreasing the grate line slope

– As the kiln capacities increased, cooler grate area became larger meaning longer grate lines and more
headroom required for installation.

III- Horizontal Cooler: It was simply developed by laying back at 10o cooler until grate line became horizontal

Although the grate line was horizontal the grates traveled up to a 10o slope during the forward travel
The conveying efficiency was reduced because of this grate motion which became one of the drawbacks
of horizontal cooler.
 Higher under grate pressures were required to maintain flow of cooling air. cl
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IV- Combination Cooler 5o slop / Horizontal

The grate line at feed end was sloped at 5o while the cooling zone grate was horizontal
This Cooler seemed to be not suitable for large capacity kiln due to material segregation phenomenon in
cooler feed end.

V- Combination Cooler 3o sloped horizontal

In order to avoid the effect of segregation and (air – sliding) of fine material, the grate line at feed
section was reduced to 3o ; however this did not eliminate both segregation and fluidization and
problem were still encountered with

2.2.2. Mechanical Features:

grate coaler mechanical features

From a mechanical stand point the cooler consists of alternate rows of per forted and overlapping
stationary and moving grates. Grate plate supports to which the individual grate plates are attached are
carried by the cooler side frame for the stationary rows and by a movable frame for the movable rows

A. Grate Plates
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grate plates

A-I- Hot Zone. Required properties:

1. Resistance against oxidation (800oC up to 1000oC)

2. Resistance against cracking
3. Good mechanical properties at high temperature (creep, deformation)

Material (25/25) or (25/20)

A-II- Middle & cold Zones: less critical problems due to lower temperature, required properties:

Wear resistance material

Material (25/12)

A-III- Manufacturing of grate plates:

Important tips:

1. Perfect in critical zones (nose and hook)

grate cooler nose and hook

1. Residual stresses: must be avoided by heat treatment for stress relieving

A-IV- Important data:

 1. Chromium (Cr): cl
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Melting point 1890oC k
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It increases the tensile strength of steels by 80-100 N/mm2 per 1% Cr
Increases wear resistance
High temperature strength

1. Nickel (Ni):

Melting point 1458oC

High temperature strength

1. Clinker hardness (500 – 700) Hv

B. Grate plate support

Grate plate supports act as a carrier for grate plates (fixed and movable)
These supports are arranged cross wise and lengthwise of the cooler

Alternating rows of fixed and movable supports cover the entire grate area(Fig.8)

fig 8

For fixed type supports it rest on cooler side frame and fixed central beam
Movable supports are attached to movable frame with weldment stands
Those supports used in hot zone are subjected to higher temperatures and possible impact of coating
chunks from the kiln, so these are designed with deep truss sections
Typical support material for this hot zone of the cooler GS 17 Cr Mo 55

Replacement of grate plates is possible from the under grate chamber(Fig.9)

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fig 9

C. Moving frame:

Moving frame is supported by shafts (running axles) and wheels (carriages) running on rails outside
cooler housing .

fig ten

Running axles: are external penetrating the cooler housing through air sealing box assembly.
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running axle

These axles are fitted with tyres

Drag (drive) shaft is fitted to the moving frame employing locking assemblies (ring feeder) in which
force is transmitted by contact pressure and friction between functional surfaces.

drag cooler

Wheels are fitted to drag shaft provided with shaft seal

At the point when the drag (cross head) shaft penetrates the cooler housing a spring loaded adjustable
sliding seal prevents loss of cooling air.
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fig thirteen

Movable frame receives its motion via connecting rods to a crank type shaft driven by a sprocket and
chain connected to a reducer with a variable speed motor.
Bearing for the cooler drive and supporting shafts are of anti-fraction type (spherical roller bearings).

D. Air compartments & flap valves:

The under grate area is divided into compartments each provided with separate fan equipped with
adjustable inlet vanes for automatic air flow and minimum power consumption.
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It’s necessary to provide a good sealing between compartment to maintain each compartment as an (air-
tight) box, so that the air can only pass upward the cooler grate and clinker bed
Clinker spillage through the grates and the gaps between them during normal operation is collected in
hoppers and removed through airtight flap valves to clinker conveyor.

discharge hopper of undergrate room

2.2.3. Grate cooler operation and control

Efficient grate cooler is not related to its mechanical design features, a very important factor is the
method used to operate and control.
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basic loops of grate cooler control

Proper cooler operation and proper protection for the cooler demands an automatic variation in damper
setting of cooler fans to provide the proper air flow at the times of steady and upset operation
conditions.
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fan with piezometer mass flow control

To maintain the proper thick bed of clinker on the grates for high cooling efficiency and recuperation to
the kiln, while at the same time protecting against excessive thickness which could produce a shortage of
air and damage to the cooler, it’s necessary that the speed of the grates be controlled automatically
Each section of the grate cooler that has its cooler own drive is independently controlled by the press of
the first compartment or second under grate comp.
The speed of the grate can be varied between 3 and 30 strokes/min
Normal operation would be around 10-15 strokes/min
After the cooling air has passed upwards through the grates, bed of clinker and is heated, it passes into a
large plenum chamber over the grates.
From this chamber the kiln by its own draft, draws part of air as a secondary combustion air.
Some other part is drawn as tertiary air for combustion in flash calciner
The balance of air not required for combustion is vented to atmosphere through a dust collector system
(graved bed system or EP.) by means of an induced draft fan.
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fig eighteen

To maintain smooth operation and avoid pressurization of the cooler, it’s necessary that the cooler vent
fan be automatically controlled by the pressure of kiln hood

Thus efficient cooler operation requires three main functions:-

1. Constant airflow to each compartment

2. Regulation of grate speed for constant bed
3. Constant negative thickness pressure in kiln hood

3- Clinker Crusher
Introduction:-

At the discharge end, the cooler is fitted with clinker crusher to break over sized particles of clinker or
pieces of coating which
Attribute to kiln upset conditions

N.B
Some grate coolers specially combined cooler with 3 grates, has the clinker crusher installed after the 2ndcgrate
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the objective here was to achieve not only the best possible quenching effect of the exposed interior surfacesk of
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the broken clinker chunks, but also the lowest possible final clinker temperature

Two types of clinker crushers are in current use:

* Hammer breaker

* Roller breaker

3.1 Hammer type breaker

clinker hammer type breaker

The clinker breaker of hammer type consists of the following:

Hammers which are cast manganese steel

Pins and spacers
Hammer hubs (discs).
Shrink fitted to crusher rotor cl
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The hammer pin is retained in its position by means of asset of collar (spacer)
The set of collar is located between two ears on the hammer
The hammers extend over the hub to give protection during operation

3.2. Grizzlies
Ahead of the breaker is a grizzly bar assembly to permit passage of mat. Of small size

One of the disadvantages of hammer crusher is the possibility of blocking in case of over sized clinker lumps

3.3. Roller Crusher

grate cooler roller crusher

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grate cooler roller crusher 3

– The roller breaker consists of several (air – cooled), hydraulically driven crusher rolls whose operation width
matches the width of the cooler grate

– The advantages of the roller crusher are:

High temp. Resistance up to (800C – 850C)

Low speed of roller rotation, reducing dynamic load on the surrounding and minimizing dust generation
Long life crushing rings
Even grain size reduction
Low power consumption

4. Problems of standard cooler

Mechanical problems
Typical mechanical problems include the following: cl
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1- Sinking of movable frame

* Due to wear on bearings and carrying rollers

2- Grate plate cracking

1. Due to incorrect grate plate material, shock load on plates during handling or by coating and finally
2. Due to over heating of plates

3- Burnt grate plates

1. Due to over heating came by snow man formation, red river, too thin layer of clinker and in sufficient
cooling air

4- Loose grate plates

1. Due to incorrect compression spring material and incorrect tightening torque of bolts

Grate plate problems

Which include the following:

Wear by sand blasting with conventional grate cooler vertical air jets cause reveres flows which catch some fines
and blow them against the grate plate surface (fig.22)
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grate cooler problems

Abrasion of grate plates: due to transportation of hot abrasive clinker

Wear of side cast plates: due to hot fine clinker flowing adjacent to side plates, causing deformation of
side frame(fig.23).

openings in traditional reciprocating grates cooler clinker

5. Developments Related to Grate Cooler

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These developments include the following :-

* Dead grates

* Reduced fall through grate I

* Air beam technology.

* Stationary inlet section.

1- Dead grate plate (bridge plates)

Dead grates were installed adjacent to the side casting on each side of the entire cooler length and
mounting to the stationary grate plate supports
The dead grate covered with castable, thus protecting the cooler side walls
The bridging plates allow deep bed operation, improving cooling efficiency

2- Reduced fall through (R.F.T) grates:

The plates were designed to reduce spillage into the under grate area by means of labyrinth in the type
slots(fig.24).
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grate cooler modifications

These slots promote the uniform distribution of cooling air into the clinker bed
Reduced fall through grates are designed to be mounted on conventional grate plate supports with open
bottoms

3- Air beam technology:

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air beam technology

Air beam systems prevent the possibility of cooling air by – passing the clinker layer.
It works by improving air distribution below the grate by connecting individual rows of the cooler directly
to the air supply
In such systems the grate plate support are used to duct, the cooling air directly to the grate plates and
into the clinker bed
Air beam system is used on both the stationary and moving rows of the cooler

4- Stationary inlet Section

This design delivers high degree of utilization and minimize overhaul maintenance costs due to
eliminating wear because of absence of any moving parts.

6. Design features of modern grate cooler:

Specific grate loading in (ton/day/m²) for the cooler as a hole is (35 – 40) (t/m². day)
Installed cooling: air quantity in the range of (3 – 3.5) Nm³/Kg with fan pressure of (60 – 70) in bar in the
first compartment, decreasing to (20 – 30) in bar in the last compartment
 Clinker bed depths range from 800mm in the inlet zone to 300mm in the outlet zone cl
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Loading to increase of plates service life k
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Limiting grate inclination for the 1st grate to a maximum of 3 degrees
Horse shoe – shaped arrangement of the plates in the inlet zone is standard to improve the clinker
distribution and control (red – river).

clinker bed depth effect on cooling

7. Grate Cooler Retrofit

Upgrading exiting grate cooler include the heat recuperation zone and in some cases extends to the
after cooling zone
The purpose of (retro fitting) (an exiting grate cooler) energy saving (reducing losses cooler & increase of
hourly by production within the overhaul dimension of exiting cooler.

8. Maintenance on Grate coolers

1. a) General Remarks
Maintenance on a cooler consists mainly of:- cl
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Planned servicing of parts (e.g. lubrication, adjustments, cleaning)
Planned detection and replacement of worn and damaged parts
Keeping control instruments functioning
Improvement of weak-points on the equipment
Keeping records on the maintenance activities

Each unit or component of the cooler shall be considered and analyzed bearing in its:-

Weak-points
Functioning and design
Effects of wear and tear
Influence of high temperature
Fatigue due to dynamic loads

By elaborating maintenance schedules the suppliers manual and instruction ought to be consulted as well as
exiting plant experiences.

1. b) Operational effects of cooler maintenance

Correct cooler operation helps keeping routine maintenance and breakdown costs low

A correct cooler operation means operating the cooler with a deep and even clinker bed:

With low grate speed resulting in low wear and tear

With high cooling efficiency resulting in reduced wear and tear as well as low temperatures on all
components

Correct cooler operation again requires correct functioning of all control, measuring and regulating equipments
(temperature, flow, pressure, speed, level, TV.,…)

1. c) Basic preventive maintenance requirements

The following suggestions require to be adapted to a given cooler, by taking into account the local condition
and the specific design characteristics of a cooler.

1- Inspection and services to be done each shift

General (walk around) inspection (leaks, noise, irregularities etc.)

Check temperature and vibration (by hand) of bearings and drives
Oil level inspection on gears
Central lubrication system, check for functioning and leaks in piping, check grease reservoir
 Check through inspection windows the functioning of the lighting, check for excessive flow of riddling
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irregularities in the under grate compartment k
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Check proper functioning of hopper discharge
Check transport of clinker and riddlings
Check fan intake for cleanliness

2- Weekly Checks and Services

Lubricate manual lubrication points

Top up lubricant reservoirs
Check functioning of control and measuring instruments (pressure, temperature, flow, TV camera)
Check tension of v-belt drives

3- Monthly vibration Measurements

Measurements on drives, fans and bearings

4- Maintenance work for a short cooler shut-down

General internal cooler inspection

Inspect the grate plates particularly the first rows of the first grate replace any cracked or damaged
plates, tighten loose plates
Inspect the lateral wear plates
Inspect the supports of the moving frame (rollers and rails)

Inspect lubrication piping for leaks inside the cooler

Inspect and adjust cooler seals (between compartments, shaft seals…)
Replace hammers if required on the clinker breaker
Inspect the grizzly bars and chains
Inspect refractory material, clean out material build-ups
Clean and service inspection windows and lighting
Clean and inspect visually control and measuring instruments
Clean and service the TV. Camera
Inspect the cooler drive
Inspect visually the hydraulic dampening gear on the moving frame
Inspect visually the fans
Tighten or replace v-belts
Inspect visually hopper discharge flaps
Inspect visually the clinker transport equipment

5- maintenance work requiring a longer cooler shut-down (once a year)

Cooler Drive (DC Drive)

 Change the oil, clean the gear and the filters and breathers cl
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Visual gear inspection k
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Check coupling alignment and general condition, lubricate if required
Retighten base bolts
Check staring clutch (if installed)
Check, clean, lubricate chain drive and tension (if installed)

6- Crank shaft, connecting rod, Drive shaft

Check all bearings and bushings for wear

Check all stop screws,keys and circular spring tensioning elemts,retighten as required
Retighten all bolts
Check sliding seal and drive shaft, check for wear
Clean and check wheel unit and guide rails, measure wear on rollers, readjust

7- Carrying Axles

Check all bearings

Check all wheel rims and guide rails for wear (measure) and fasten, readjust as required
Check the sealing unit and service as required
8- Moving Frame

Check alignment of the frame (leveling and clearances) realign if required.

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moving frame great cooler

Check movement of the frame (no contact between fixed and moving parts, observe clearance for
thermal expansion)
Check for thermal overload deformation and cracks
Check partition walls and sealing
Check lateral moving frame guides

9- Grate Components

Check grate plates, grate supports, side castings and/or support bracket plates, end castings and/or
cover bracket plates for wear cracks or damage. Burnt, worn or damaged parts have to be replaced

Note: Replace grate plates of the first 4 rows, if possible use the old plates which are not damaged for
replacement of plates in the lower grate section.

Check all mounting bolts for tight seat

Check mounting and functioning of thermo-couples

10- Clinker Breaker

 Clean and check bearings (Fig.31 A,B), measure clearance, fill with new grease, replace seals, checkcseat
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of bearings of shafts, tighten bearing base bolts. k
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clinker crusher

Check rotor, hammers and pins, replace hammers and balance rotor
Check functioning of rotor motion switch
Check v-belt drive, change v-belts, align and tighten base bolts
Check impact plate, chain curtain, grizzly and clinker discharge chute for wear and damage clean grizzly

11- Clinker Transport, Drag Chain

Check, clean and service drive, replace v-belts, realign and tighten base bolts, change oil, check shear pin
Clean and check all bearings, refill with new grease, tighten base bolts of housing, replace seals
Check sprockets, idlers and tail drum for wear (measure)
Check chain links for wear, cracks or damage, renew armoring if necessary, tension chain
Check chain supports for damage and wear
Test-run the chain drive

12- Clinker riddling Hopper and double Flap Gates

Check and clean hopper

Check functioning of level indicators
Check double flap gate, check wear on flaps seals, adjust for proper sealing, check functioning, check flap
drive and service as required

13- Central lubrication System

Clean and check pump and control components, test functioning

 Clean and refill grease tank cl
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Check lubricant distributors k
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Clean filters
Check lubrication points, pipe work and pipe protections, replace flexible hoses if required

14- Fans

Check wear on impeller, repair or replace and balance if necessary

Check and clean the casing and the air intake and ducting
Seal all ducting
Rinse and check all bearings, refill with grease
Check v-belts, replace, tension
Check v-belt pulleys and guards
Check air flow controller including actuator

15- Measuring, Regulating and control Equipment

Service and check functioning

16- Brick Work

Clean suspended arch at top remove any material deposits

Check suspended arch, suspending structure, casting, bricks
Check brick lining of the cooler side walls including wear zone in the grate area

17- Cooler Casing and Ducting

Inspect for damage, wear and leaks

Replace seals as required
Check insulation

18- Dedusting equipment

See special instruction

1. d) Maintenance record Keeping

All relevant preventive and corrective maintenance activities on the cooler shall be entered in the machine
history.

Grate plate record

Damaged plates
Replaced plates
 Modifications cl
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Plate wear k
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Refractory material
Damaged
Replacements
Modifications
Moving frame alignment
Alignment measurements
Lateral clearances
Rail and roller diameter (wear)
Vibration measurements
Fans
Drives

please contact me as soon as you finish reading this article : [email protected]

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8 thoughts on “Grate Cooler”

JASON BACK
FEBRUARY 20, 2017 AT 1:44 PM
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Hot blast valves for air heaters of blast furnaces. Cement industry equipment . The grate cooler is intended i t
for cooling of clinker, alumina and other bulk materials by atmospheric air.

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GATE RESULT
FEBRUARY 23, 2017 AT 4:49 AM

Usually I don’t learn post on blogs, but I wish to say that this write-up very pressured me to check out and
do so!
Your writing style has been amazed me. Thanks, quite great
post.

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VIJAYBHAN
FEBRUARY 24, 2017 AT 2:55 AM

Very excellent & fine article

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HOMESCHOOLING
FEBRUARY 26, 2017 AT 10:47 AM

Great blog right here! Additionally your site quite a bit up fast!

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DEPT OF EDU
MARCH 26, 2017 AT 3:11 AM

Appreciating the time and energy you put into your blog and detailed information you provide. It’s nice to
come across a blog every once in a while that isn’t the same outdated rehashed information. Wonderful
read! I’ve saved your site and I’m including your RSS feeds to my Google account.

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AHMAD NILFOROUSHAN
NOVEMBER 1, 2017 AT 9:18 PM

Excellent, article has very useful explanations for amator engineers and operators.

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SCSHARMA
DECEMBER 23, 2017 AT 6:42 AM

require solution for bull nose castable failure in grate cooler

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DJELLAL ABDELHAMID
FEBRUARY 10, 2019 AT 4:06 PM
 hello, I would like if possible to get some technical details about a replacement of a planetary cooler inc a
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clinker kiln, with a grate cooler one.what are the prliminary preparation jobs to do, mechanical, civil works k
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,etc.
Can I have an estimation of the time for such a job fromclinker to clinker, for an FLSmidth 1500 tpd kiln.
Is it necessary to change the kiln shell, invert kiln live rings ? all the information is interesting to know ,such
a way we can succeed in this replacement. Thanks in advance

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