we have 3300tpd FLS plant, last year it was upgraded to 4000TPD capacity without any modification of Grate cooler. we are producing 4000tpd OPC clinker but the clinker temp is very high 250C after cooler.The only change done in cooler was instead of first grate 6 more grates were made stationary. Since upgradtion we are facing the problem, that extreme corner grate plates in 2nd chamber of the cooler are dislarging due bolts are getting shear.Is clinker high temp have any link with these bolts damaging?

It is likely that the 20% increase in the load on the cooler and the resultant elevated temperatures are a cause of the shearing of the bolts of the extreme corner plates of the 2nd chamber of the cooler. Has increased expansion allowance been provided for the grate plates operating at these elevated temperatures?

   Dear Michael Clark :

No increased expansion allowance was provided.What do you recommend us to solve this problem.

Dear Amir, My first step would be to ask FLS for their advice.

Dear Amir,

It seems that plant capacity has been increased and there was not enough margin available to handle the extended capacity by cooler. That's why you are getting clinker temp so high.

There are many types of plates anr available for grate coolers.

First let me know what is the type of plate you are using. Is is plate directly fixed to beam or it is mushroom type plate.

Which bolt is getting sheared is it fron bolt or back side on, normally it happens at front side only.

As on given condition, you can do two things, which can be done in any planned stoppage

1. Re-check al the bolts oreintaion with proepr washer and tight at rated torque. Run the cooler for 8-12 hrs and retight all the bolts one more time.

2. Provide some locking arrangemt for bolts by putting a plate connecting two bolts or any other method.

Befor bolt get shear, it will loose and then only it will shear. So you have to arrest the loosening of bolts.

And as you have mentioned, the proble is in extreme end, proper tightening of bolts will resolve the problem. As there is not enough space availble for tightening and normally because of ductiongs inside the undergrate chamber these area bolts are not tighten properly.

 

Dear Mr. Amir,

As per my experience your cooler 2nd chamber bolts get damaged may be due to uneven material movement inside the cooler, fine hot clinker segregation causes Red River formation.You should rearrange your cooler plates.

As per my rough calculations your cooler-efficiency is around 55% and you may be losing 25 - 30 Kcal/ kg clinker due to your inefficient cooler.

Why don't you go for IKN cooler types to recover more heat and less damage to your cooler plates...?

Vikpro

Dear Mr. Feroze Kindly ,

To  improve the plant performance ( Upgrading ) , ,. Process optimisation must be

 covers the potential capacity of the plant and measures to achieve the same.

 Optimisation of grate cooler operation the first point you need to improve your plant performance .

To obtaining that you have to

Installation of variable speed drive for cooler fans and one of the cooler

exhaust fans.

Extension of clinker cooler area by provision of 3rd grate and increasing the

capacity of cooling air fans Or You can optimising your grate plate design specially at hot zone aria .

My best guess you working with colax grate cooler and the main cause of your bolt damaged is due to thermal stresses and thermal fatigue ( Cracks )as result as increasing of production rate and backward clinker pushing ( grate shape design )

And to increasing somebody experience i need to add there are no ways to optimising in feeding rate with red rever or others problems the clinker`s cooleres always  limit the plants productions with these problems  .

I have had same problem , Slop and retaining ribs with helical spring mounting (  changing in grate plate design ) , And best heat recovering ( facilitates air distribution )

That could fix your complete problems

Best regards

ILA

rd grate and increasing the

capacity of cooling air fans Or You can optimising your grate plate design specially at hot zone aria .

My best guess you working with colax grate cooler and the main cause of your bolt damaged is due to thermal stresses and thermal fatigue ( Cracks )as result as increasing of production rate and backward clinker pushing ( grate shape design )

And to increasing somebody experience i need to add there are no ways to optimising in feeding rate with red rever or others problems the clinker`s cooleres always  limit the plants productions with these problems  .

I have had same problem , Slop and retaining ribs with helical spring mounting (  changing in grate plate design ) , And best heat recovering ( facilitates air distribution )

That could fix your complete problems

Best regards

ILA

Installation of variable speed drive for cooler fans and one of the cooler

exhaust fans.

Extension of clinker cooler area by provision of 3rd grate and increasing the

capacity of cooling air fans Or You can optimising your grate plate design specially at hot zone aria .

My best guess you working with colax grate cooler and the main cause of your bolt damaged is due to thermal stresses and thermal fatigue ( Cracks )as result as increasing of production rate and backward clinker pushing ( grate shape design )

And to increasing somebody experience i need to add there are no ways to optimising in feeding rate with red rever or others problems the clinker`s cooleres always  limit the plants productions with these problems  .

I have had same problem , Slop and retaining ribs with helical spring mounting (  changing in grate plate design ) , And best heat recovering ( facilitates air distribution )

That could fix your complete problems

Best regards

ILA

rd grate and increasing the

capacity of cooling air fans Or You can optimising your grate plate design specially at hot zone aria .

My best guess you working with colax grate cooler and the main cause of your bolt damaged is due to thermal stresses and thermal fatigue ( Cracks )as result as increasing of production rate and backward clinker pushing ( grate shape design )

And to increasing somebody experience i need to add there are no ways to optimising in feeding rate with red rever or others problems the clinker`s cooleres always  limit the plants productions with these problems  .

I have had same problem , Slop and retaining ribs with helical spring mounting (  changing in grate plate design ) , And best heat recovering ( facilitates air distribution )

That could fix your complete problems

Best regards

ILA

hello mr amir feroze

> you try this slowly slowly  by observing put the burner in up to 100mm by 25mm steps

and then see the result also observe clinker temp i hope that it will drop.

> 2nd check your cooler bed and caculate your cooler air volume.