BURNING

TECHNOLOGY

PT INDOCEMENT TUNGGAL PRAKARSA Tbk.

Burning Technology

1. Rotary kiln operation

2. Fundamental Combustion
3. Cooling process
Cooling Process

Several type of clinker cooler :

Rotary cooler
Planetary cooler
Grate cooler
Functions of Clinker Cooler

1. Quench clinker entering the cooler

- Influence in microscopic structure
- Mineralogical composition
- Grind ability in the cement mill
2. Recuperation of heat
- In clinker discharging from kiln to cooler
3. Conveying of clinker
Goal

1. Lower specific cooling air input

2. Enhance heat recuperation
3. Minimize red river
4. Increase grate plate life
5. Increase cooler availability
6. Improve clinker distribution
7. Increase cooler specific loading
Goal

8. Lower Specific energy consumption

9. Reduce clinker fall through
10. Reduce maintenance cost
11. Better kiln stability
 Cooling Process

Base on Mr. Kent Martin (HTC) research

Todays clinker size for 50 MTPD/m2
Target 65oC + ambient clinker temp.
Grate loading of 60 MTPD/m2
Target 100oC + ambient clinker temp.
Cooling Air Load
Air Distribution
Air Distribution Velocity

C1 (Cooler Throat) : 5-6 m/sec

C2 (Above Grate) : 10-12 m/sec
C3 (TAD w/o Settle. Ch) : 5-6 m/sec
C3 (TAD w Settling. Ch) : 8-10 m/sec
C4 (Hot Air Take Off) : 8-10 m/sec
C5 (Exhaust Air) : 8-10 m/sec
Air Distribution Simple Calculation

Following step below :

Measuring static and dynamics pressure
- Tertiary Air Duct
- Hot Air Take Off
- Exhaust Air
Measuring temperature
Measuring cooling fans velocity
Measuring cooling fans horn diameter
Establish Nm3/kcal combustion air minimum
Design Feature

Clinker segregation
Static and fix inlet
Improved grate plate design
Mid-cooler hot roll breaker
Clinker Segregation

Clinker size distribution

1. Depend on kiln rotate
direction
2. Depend on kiln rotate
speed
3. Depend on kiln and
cooler axis
Clinker Segregation

Fines clinker will

give cooling air less
opportunity to
penetrate clinker bed

Coarse clinker
provide bigger room
for cooling air to pass
through clinker bed
easily
Clinker Segregation

Those figure above shows different type of clinker

bed distribution. Left side shows unbalance
condition which in the future could create red
river, unstable secondary air, etc. Right side
shows better condition. How to do it?
Clinker Segregation

There are several way to minimize that effect :

Establish different amount of flow of each
cooling fans. On the left side (depend on kiln
rotation) use higher flow cooling fan than
right side.
Tight room seal between those cooling fans
Produce homogenous clinker segregation
Appropriate static horse shoe construction
Develop new technology (MFR)
Clinker Segregation

Tight
Room
Seal
Higher Capacity
Clinker Segregation

Horse shoe
Construction

Width

Length
Clinker Segregation

o MFR (Mechanical
Flow Regulator) was
developed by
F.L.Smidth.
o Principally, it work
base on gravity.
Static and Fix Inlet

Create 2 layer type of clinker in term of

temperature. Hot clinker in surface and
cold clinker above grate plate
Represent the thickness of bed clinker
(pressure chamber/fan measurement) in
case the clinker is distributed well.
Clinker movement is depending on the
slope of grate plate (gradient)
Static and Fix Inlet
Static and Fix Inlet

Buffer Area
Static and Fix Inlet
Ready for clinker
Improve Grate Plate Design

Pocket type grate

plate
Typically have
longitudinal slots
Forcing air to blow
downwards into
grate plate pockets
Improve Grate Plate Design

Fullers CFG Grate

Plate and Support
Improve Grate Plate Design

Horinzontal
tranverse slot design
Air leaves the grate
plate through
horizontal tranverse
slots
Forming jets of air
Blown through the
clinker layer
Improve Grate Plate Design
IKN Coanda Grate Polysiuss Jet Stream Plate
Mid-Cooler Hot Roll Breaker
Mid-Cooler Hot Roller Breaker

Uniform clinker temp. and size to all

finish mill
Reduced power consumption in finish
grinding system
Coarse clinker will be cooled sufficiently
to be conveyed by rubber belt after
clinker storage area
Mass and Heat Balance
Mass and Heat Balance