Snowman formation is a common feature with modern, direct-aerated coolers due to the high secondary air temperature achieved and therefore residual liquid content in the clinker entering the cooler. It is usually controlled with big blasters. Some cement companies have deployed a mechanical “pusher” to clear the snowmen.
first i thing u must keep the bed of material at the first grate higher, this will help and the temp of secondary air. second: do not increase the temp of the burning zone couse the liquid phase will encrease, speek with lab people to controll the liquid phase better.try to reduce the dust of kiln hood. if any body know more i am a new engineer and want to lear more. thanks bye