ETA Cooler vs.

Grate Cooler

Jens Garbe
Territory Sales Manager
Presentation for Qatar National Cement Company
dated 02.11.2011

A Langley Holdings Company Claudius Peters Projects GmbH

 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

Claudius Peters – Experts in Clinker Cooling

Successful figures worldwide…

735
228

Cooler
112
Conversions
coolers since 1950
HE-
HE-Module installations
since 1994
…for more than 60 Years

A Langley Holdings Company Claudius Peters Projects GmbH

CP Clinker Cooler Evolution

Claudius Peters Originator

► Hydraulic Drive 1976

► Roller Crusher 1978

► 10.000 tpd Cooler 1992

► Compact Swing Support 1998

► ETA Cooler 2004

A Langley Holdings Company Claudius Peters Projects GmbH

 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

High Efficiency Module (Static Inlet)

Protection
Static layer protects the grate
plates of the HE Module

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Principle of Movement
Movement pattern example with 4 lanes

1 2 3 4

Forward
Step 1
stroke

1 2 3 4

Step 2

Backward
Step 3
sequence

Step 4

Worldwide patents applied / pending

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Self-Protective Design against Wear and Heat

Hardfacing

Clinker bed

Wear protection

93 % protected by simple stones

remaining ribs hardfaced

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 Stroke Length / Cycles of CP ETA Cooler

[stroke length mm] [stroke cycles / min]

250 15

200 12

150 9

100 6

GRATE
GRATE

50 3
ETA

ETA
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Holcim Siggenthal after 4 years of Operation

Only paint is off

the cooler is ready
for production

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Self Protection Summary

1: HE-Module:
HEM-Plates are protected by a static clinker layer
2: Aerated Lanes:
93% of the surface is covered with simple stones
• protection against mechanical wear
• protection against heat damage
3: Stroke length / Cycles:
Long stroke length causes slow movement which reduces
wear

A Langley Holdings Company Claudius Peters Projects GmbH

 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

Segregation Effects due to Kiln Rotation

Coarse clinker side, low pressure drop

Fine clinker side, high pressure drop

Tendency to develop a red river

on the coarse and fine side

Coarse Fine
clinker clinker

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Clinker Cooling Curve
Big influence at the front
of the cooler
Small influence at the end
of the cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Red River of Traditional Cooler

Typical Grate Cooler Troubles:

Hot fine clinker reaches end of the
cooler
High wear on grate plates
Hot air flows in exhaust air duct
Clinker is not cold at the end of the
cooler
Recuperation is not optimum.

NO Grate cooler can influence the

clinker flow over the cooler width!

YES ETA CAN!

A Langley Holdings Company Claudius Peters Projects GmbH

Static Inlet High Efficiency Module

Static clinker layer protects the plates

Vessel system minimises pressure loss
Flexible air control with small aeration
fields
Targeted aeration in the beginning of the
cooling curve

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HE-Module Installation

Simple rigid design

Pre-assembled unit
Shortest possible installation time

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Aeration Scheme
1,2m 1,4 m 2,2m 2,2m 3,3 / 4,4 m
HEM
CSA

CSA
Recuperation zone Cooling zone

1. High Efficiency –Module (HEM)

2. Controlled Side Aeration (CSA)
3. Individual Stroke Length

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Process Optimized Aeration

1: HE-Module (HEM):
Small aeration fields ensure precise and adjustable aeration
in the drop zone
2: Aeration Chambers:
Small aeration chambers at the cooler front,
bigger chambers further down the cooler;
>> corresponds with the clinker cooling curve
3: Chamber Side Aeration (CSA):
Longitudinal Chambers Left and Right to prevent red river
4: Individual Stroke length:
Shorter stroke length on the sides to prevent red river
A Langley Holdings Company Claudius Peters Projects GmbH
 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

Modular Design

Essential design features:

fully modular constructed
standard sizes
flexible module arrangement for existing plants
pre-assembled modules to site

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Semi-Modular Design
HE-Module
Grate plates

horse shoe air distribution with

refractory measuring devices

lane units
With sealings

hydraulic drive

HE-Module roller units with

steel work cross traverse

partition walls

CP supply
lower side walls
Possible local or customer supply

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Module Installation

Modules per Truck on Site

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Overview Modular vs. Semi-Modular
Modular Semi-Modular

Portion CS / local Low High

Pre-manufactured Yes No

Key components CPP CPP

Steel work / lower part CPP Local / Customer

Quality control 100% CPP Partial local

Assembly Shortest Extended

Handling / transport cost Higher Lower

A Langley Holdings Company Claudius Peters Projects GmbH

 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate
Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

Traditional
Modern ETA Cooler
Grate cooler

Bed height 800 mm 600 mm

Retention Time
35,8 min 26,9 min
@ 45 t/d/m²

Power consumption 6,76 kWh/t clinker 5,9 kWh/t clinker

Cooler efficiency 77% 75,4%

Clinker bed =Power consumption

= Cooler efficiency

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Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

Comparison ETA versus Grate cooler

A Langley Holdings Company Claudius Peters Projects GmbH

 Introduction ETA Cooler

1. CP Clinker Coolers
2. ETA Cooler
Self Protected design
Process Optimised Aeration
3. Delivery
4. Comparison ETA vs. Grate Cooler
5. References

A Langley Holdings Company Claudius Peters Projects GmbH

Overview ETA References

ETA Cooler sold 50

Replacing conventional cooler 19
Replacing satellite cooler 4
Behind wet kilns 3
Cooler in backward design 2
ETA Cooler as stage cooler 15
ETA Cooler as a base for
15
waste heat recovery
ETA Cooler in operation 37
Min. Capacity 700 t/d
Max. Capacity 13,000 t/d

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Performance results
World Cement 08-2010

Herr Gasser.Assistant Vice President HGRS: concerning Siggenthal:

The ETA cooler created new potential for more secondary fuel. In 2005 a
thermal substitution of up to 40 % could be achieved at an average kiln
capacity of 1905 t/d, using solvents, animal and bone meal, dry sewage
sludge and old tyres while kiln operation became more stable.

A Langley Holdings Company Claudius Peters Projects GmbH