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From Hot to Cool

Published by , Editorial Assistant
World Cement,


In the complex world of cement production, the efficiency of each step significantly impacts the overall process. One crucial aspect is the cooling of clinker, an essential intermediate product in cement manufacturing.

Clinker demands rapid and effective cooling to preserve its quality and characteristics. Traditionally, air cooling with fans has been the standard solution. However, water injection systems have long been utilised as an effective method for cooling clinker gas.

Water injection systems operate by spraying water into the clinker cooler. The water rapidly evaporates, absorbing heat in the process and thus aiding in quick cooling. This method not only accelerates the cooling rate but also helps prevent thermal stresses, ensuring the quality and integrity of the final cement product. One often overlooked benefit of water injection systems is their impact on gas volume. As water evaporates in the clinker cooler, it cools the gases, leading to a reduction in gas volume. This reduction decreases the load on downstream equipment, such as baghouse filters, improving operational efficiency, reducing the electricity consumption of the ID fan, and lowering maintenance requirements. Alternatively, it increases the plant operator’s flexibility to enhance production capacity.

While the concept of water injection in clinker cooling is not new, its importance is still underestimated. By strategically injecting water into the clinker cooler, manufacturers can achieve precise control over the cooling process, ensuring uniform temperature distribution and optimum cooling efficiency. Water injection systems provide the flexibility to adjust cooling rates according to production demands and clinker compositions, making them a valuable asset in cement production facilities worldwide.

This article delves into a practical case study of a French cement plant that sought to enhance its clinker cooling process. Collaborating with Lechler, a specialist in spray systems, they utilised advanced techniques to improve their cooling system. This case study illustrates the enduring significance and effectiveness of water injection systems in cement manufacturing, from the initial assessment to practical application. The project is examined, delving into the design considerations, challenges faced, and solutions developed along the way. This case study provides valuable insights into the impact of advanced engineering on the future of cement production, from the initial CFD analysis to the final equipment supply.

Project overview

A well-known international cement group’s cement plant in France recently initiated a project to improve the effectiveness of their clinker cooling process. Traditional air cooling methods were insufficient to meet the demands, which prompted an OEM to seek an advanced solution from Lechler. This required managing significantly different cooling amounts and achieving specific outlet temperatures while accommodating the unique design of their clinker cooler. The need for a high flow rate of the water injection system added another layer of complexity.

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Read the article online at: https://www.worldcement.com/special-reports/30122024/from-hot-to-cool/

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