Clinker Cooler Optimization

The clinker cooler is an essential part of a cement plant. Its function is to cool down the red hot clinker discharged from the kiln. Various designs of clinker cooler are under use in the industry, of which, the grate coolers are the most common. In a grate type clinker cooler the clinker at temperature as high as 1350°C falls on a series of stationary and reciprocating grates. Pressurized cool air is made to flow beneath the grates, which takes up most of the heat of the clinker as it rises and finally circulated to the preheaters. The clinker is usually cooled at rapid rate and brought down to temperature around 150°C. This is a necessity since the clinker has to be conveyed over rubber belts, to silos or grinders. Faster cooling rate of clinker is also important because it is a determinant factor which decides the strength as well as setting rate of cement and grindability of clinker.

       

Application

As mentioned above, the clinker cooling rate is a parameter of primary concern and thus, needs to be continuously controlled. The factor that affects the cooling rate the most is the thickness of clinker 'bed' over the cooling grates. The speed of cooler fans and the reciprocating grates are controlled by this parameter. several techniques have been developed over time to monitor the thickness of clinker bed-the most common of these include temperature sensors and differential pressure transmitters that monitor the flow rate of aiur inside clinker cooler. The flow of air is directluy related to the thickness of clinker bed howevere, a wrong assumption may be made becauyse of the changing material sizes. A more reliable solution ius available by employing a high sensitivity Radar system that continuosly monitors the clinker bed thickness. The Radar Level transmitter is not affected by dust and changing temperature. 

 

Technology

The pulse Radar Level transmitter LTR56 emits pulses of high energy microwaves. These pulses, with frequency of the order 26 GHz, are emitted at nanosecond intervals to hit the clinker bed and reflect back to the antenna. The time of flight of reflected waves is recorded continuously by the pulse timer inside the level transmitter. The high precision microcontroller multiplies the time of flight with the speed of light and gives the thickness measurements. The Radar Level transmitter is provided with a bent antenna extension to protect the electronics from high temperature. Also, integral air purging is provided to avoid the material buildup on antenna.

 

Benefits from TIPL LevelExpert LTR56

  • Compact size- ease of installation and maintenance
  • Unaffected by temperature and dust
  • SS316 horn antena with integral air purge for longer life
 

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