Cement, Energy and Environment

35 A brief analysis of impact of energy saving technologies on CO2 reduction states that approximately 6 kg CO2/t of cement can be reduced upon deployment of high efficiency cooler. In this stake KHD has done various successful modification to improve the efficiency of KHD cooler which are summarised in coming section. HIGHLY DEVELOPED CLINKER COOLER PARTS FOR LATEST GENERATION COOLER PFC² To increase efficiency and plant availability and to reduce maintenance costs at the same time, KHD Humboldt Wedag has developed the PYROFLOOR® cooler two decades ago. As this third-generation clinker cooler, affecting the efficiency of a cement plant it has a wide impact on the thermal and electrical consumption of the produced product. Eventhoughthefirst transitionofaKHDPYROFLOOR® cooler (PFC) towards the PYROFLOOR2® (PFC²) has already been achieved, an improvement of PFC² clinker cooler parts is still an ongoing process. In the following sections, experiences are discussed with existing clinker cooler parts and its evolution into the latest new PYROFLOOR2® parts. This offers evenhigher state of process efficiencies, maintainability and reliability of a clinker cooler. COOLER CASSETTES DESIGN FACTORS The basic concept of a walking floor cooler design is the modular setup of the movable grate. In PFC, part of this is the aeration cassette which has to ensure: • Preventing fall through (leakage) of fine clinker particles for keeping the the undergrate compartment need and clean. • Generating as less as possible pressure loss for reducing the power consumption and investment cost of cooling air fans. • Avoiding any relative movement between clinker particles and metallic surfaces for less wear (providing autogenous protection). The marked is further demanding a very low pressure loss therefore the KHD´s engineers were targeting optimized cassette design to reduce pressure loss. Following features were implemented: • Aeration slots design optimized for reduced pressure loss. • Perpendicular to the direction of clinker flow. • Maintains the USP of autogenous wear protection. • Shall be installed using adapter frames on the existing top modules (ready for modification projects). In the following slides the existing PFC² aeration cassettes and the new developed optimized cassettes so called “Opti Cassettes” are shown. Design Features PFC Cassettes