Grate Plate Pocket Design for Cement Clinker Cooling
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Solution Overview
Problem
Existing grate cooler designs face high air resistance and energy costs due to meandering cooling air channels and complex manufacturing processes, with high wear and tear on grate elements from abrasive cement clinker, leading to increased production costs and inefficient cooling.
Innovation Solution
A grate plate design with a large opening diameter of at least 7 mm for cooling air introduction and a pocket system for autogenous wear protection, featuring a stable bed of cement clinker granules with small mesh sizes and angled openings to reduce air resistance and wear, along with a replaceable thrust edge and wear protection layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If meandering cooling air channels are used to cool hot bulk material, then cooling effectiveness is improved, but air resistance increases and energy costs rise
Solution Approach 1:
The grate plate is divided into multiple pockets (2) that hold cooling air channels, creating segmented cooling zones. Each pocket contains a separate cooling air channel (4), allowing cooling air to be distributed through multiple discrete paths rather than a single meandering channel, reducing overall air resistance while maintaining cooling effectiveness
Solution Approach 2:
The invention transitions from a two-dimensional surface cooling approach to a three-dimensional cooling structure by incorporating vertical pockets (2) that extend into the grate plate thickness. Cooling air channels (4) are positioned at the bottom of these pockets, creating a multi-level cooling system that reduces air resistance by providing direct vertical cooling paths rather than horizontal meandering paths
2Strength
If complex manufacturing processes are used for grate plates, then structural integrity is improved, but production costs increase
Solution Approach 1:
The grate plate is segmented into multiple identical modular units, each containing pockets (2) with cooling air channels (4). These modular sections can be manufactured separately using standardized processes and then assembled together, simplifying manufacturing while maintaining overall structural integrity through the modular design
Solution Approach 2:
The grate plate incorporates a porous structure with multiple pockets (2) and cooling air channels (4) that allow cooling air to pass through. This porous design is achieved through relatively simple manufacturing processes such as punching and folding profile steel sheets, avoiding complex machining while maintaining structural integrity
3Reliability
If grate elements are made with high wall thickness to reduce wear, then wear resistance is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The invention introduces an intermediary protective layer - the autogenous wear protection layer formed by cement clinker granules held in pockets (2). This layer acts as a mediator between the abrasive bulk material and the grate plate surface, protecting the grate elements from direct wear without requiring increased wall thickness or complex wear-resistant coatings
Solution Approach 2:
The system uses the bulk material itself (cement clinker granules) to protect the grate elements from wear. The granules are held in pockets (2) and form an autogenous wear protection layer that continuously protects the grate plate surface during operation, creating a self-service wear protection mechanism that eliminates the need for complex protective structures
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 reduces air resistance, lowers power consumption, minimizes wear, and decreases production costs by forming a stable bed of cement clinker granules with low air resistance, maintaining efficient cooling and extending the service life of grate plates.
Implementation Method 1
the area alternately covered by a further grate plate is largely covered by the at least one pocket (2) for holding bulk material (3) as an autogenous wear protection layer
Implementation Method 2
The cooling air then flows through the hot cement clinker layer and absorbs the heat from the cement clinker
Implementation Method 3
pass cooling air through the bed of bulk material using the cross-flow process
Implementation Method 4
the static, cooled cement clinker layer in the pockets serves as thermal insulation, so that the grate elements have a higher surface hardness at a lower temperature
Data Source
Figure 1~2
Figure 3~6
AI summary
The invention relates to a grate plate (1) for use in a bulk material cooler for hot bulk material (3), such as for example hot cement clinker, having a working region with at least one pocket (2) for holding bulk material (3) as an autogenic wear protection layer, at least one opening (4) which leads to the underside (5) of the grate plate (1) for supplying cooling air (6), wherein the working region has, when used in a grate cooler, a region which is alternately covered by a further grate plate (1). The invention provides that the area alternately covered by a further grate plate (1) is also covered for the most part by the at least one pocket (2) for holding bulk material (3) as an autogenic wear protection layer, and that the at least one opening (4) which leads to the underside (5) of the grate plate (1) for supplying cooling air (6) has a clear opening which has a diameter of at least 7 mm or more. By this means, the grate plate has a low air resistance and the air resistance varies less during use.