Clinker Cooler Tilted Grate Vertical Shearing
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Solution Overview
Problem
The existing coolers for particulate material subjected to heat treatment in industrial kilns face a 'cold channel' problem due to uneven air flow resistance, leading to inefficient heat recuperation and accelerated cooling instability, which diminishes the heat recovery process and increases fuel consumption.
Innovation Solution
The cooler design incorporates tilted mounting devices with a specific angle and length to enhance vertical shearing, ensuring a consistent clinker bed height and air flow distribution, preventing cold channels and improving heat recuperation by maintaining a balance between air flow and clinker movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is used to cool the clinker bed, then cooling efficiency is improved, but uneven air flow distribution occurs creating cold channels that reduce heat recuperation
Solution Approach 1:
The patent introduces local variations in the clinker bed structure by creating channels with different fill levels. The grate plates are positioned at different heights relative to the clinker bed surface, creating zones with different air flow resistance. This local quality variation ensures that air flow is distributed more evenly throughout the bed, preventing the formation of cold channels while maintaining efficient cooling.
Solution Approach 2:
The patent employs a moving bed mechanism where the clinker bed is continuously moved forward on the grate plates. This dynamic movement prevents the establishment of stable cold channels by constantly changing the flow paths and resistance distribution. The bed material is replenished from the inlet and discharged at the outlet, maintaining a dynamic equilibrium that promotes uniform air flow distribution.
2Loss of energy
If the clinker bed height is increased to improve heat recuperation, then heat exchange efficiency is improved, but cold channel formation is accelerated
Solution Approach 1:
The patent segments the clinker bed into multiple zones with different characteristics by varying the grate plate positions. The bed is divided into sections where some areas have higher clinker levels and others have lower levels, creating a segmented structure that promotes uniform air flow. This segmentation prevents the formation of continuous cold channels while maintaining sufficient bed height for effective heat recuperation.
Solution Approach 2:
The patent changes the physical parameters of the system by varying the grate plate heights and positions along the cooler length. This creates a non-uniform bed structure where the air flow resistance is distributed more evenly. The parameter changes in grate plate positioning allow the system to maintain stable cooling despite variations in bed height, preventing cold channel formation.
3Stability of the object's composition
If vertical elements are added to create pockets of stationary clinker, then vertical shearing is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the vertical shearing function from complex mechanical elements and achieves it through the inherent movement of the clinker bed itself. By utilizing the natural flow and replenishment of clinker material, the system achieves vertical mixing and shearing without requiring additional moving parts or complex mechanisms. The vertical elements are simplified to passive structures that guide rather than actively move the material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves improved heat recuperation by maintaining a consistent clinker bed height and air flow distribution, preventing cold channels and enhancing the overall cooling efficiency while reducing fuel consumption by optimizing the heat exchange process.
Implementation Method 1
cooling gas is injected upwards between the bottom (8) and the lanes (10), the cooling gas is going through grate plates (12) in the lanes (10), the cooling gas is then passing through the material (2)
Implementation Method 2
The friction force from the stationary clinker above the two stationary neighbouring lanes will ensure that the clinker above the moving lane has at least only moved back a fraction of the distance which the lane is moving. Hereby the transport of the clinker is established. The clinker above the moving lane will be forced over the vertical element.
Data Source
AI summary
The present invention discloses a cooler for cooling particulate material which has been subjected to heat treatment in an industrial kiln, such as a rotary kiln for manufacturing cement clinker. This cooler comprises an inlet, an outlet, end wall, side walls, a bottom and a ceiling, at least three reciprocating supporting lanes for receiving, supporting and transporting the material to be cooled, the lanes are moving following the walking floor principles as well as means for injecting cooling gas into the material through grate plates in the lanes. With the present invention it is an aim to have an increase in the vertical shearing height, and still having stationary clinker on top of the grate plates.