Rotating Clay Conduit Cooler With Integrated Coolant Channels
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Solution Overview
Problem
Existing calcined clay coolers are inefficient in cooling calcined clay from rotary clay kilns, leading to high coolant consumption and energy loss.
Innovation Solution
A calcined clay cooler with rotatable clay conduits and integrated coolant channels enhances heat transfer by rotating conduits around an axis, allowing for symmetric conduit arrangement, direct heat exchange, and optimized coolant flow to reduce coolant consumption and energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If spray cooled drum shell is used for cooling calcined clay, then cooling function is provided, but coolant consumption is high and cooling efficiency is low
Solution Approach 1:
The cooler is divided into multiple independent cooling zones along the clay flow path, with each zone having adjustable cooling intensity. This segmentation allows optimized coolant distribution, reducing overall coolant consumption while maintaining effective cooling throughout the clay material.
Solution Approach 2:
The cooling system incorporates adjustable cooling intensity that can be dynamically modified along the clay flow path. The cooling parameters can be adapted to match the thermal state of the clay at different positions, improving cooling efficiency while minimizing excessive coolant usage.
2Loss of energy
If rotary kiln is used for calcining clay, then pozzolanic material is produced, but thermal energy recovery is insufficient
Solution Approach 1:
The system implements thermal feedback by using the thermal energy from exiting clay to preheat the incoming raw clay material. This feedback loop recovers thermal energy that would otherwise be lost, reducing the overall energy input required for calcination while maintaining production capacity.
Solution Approach 2:
Incoming raw clay is preheated using thermal energy from the cooler outlet before entering the calcination zone. This preliminary thermal preparation reduces the energy demand in the main calcination process, improving overall thermal efficiency without compromising productivity.
3Area of stationary object
If conventional cooler design is used, then clay cooling is achieved, but cooler footprint is large
Solution Approach 1:
The cooling function is extended into the vertical dimension by implementing multi-level cooling zones and three-dimensional heat exchange structures. This vertical utilization of space achieves effective cooling within a smaller horizontal footprint, concentrating the cooling function in the vertical direction.
Solution Approach 2:
Multiple cooling functions are merged into a single integrated cooler structure that performs both primary cooling and thermal energy recovery in one compact unit. This consolidation of functions reduces the overall footprint compared to separate cooling and energy recovery systems.
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
The solution improves cooling efficiency, reduces coolant usage, minimizes the cooler's footprint, and recovers thermal energy for reuse, contributing to reduced CO2 emissions and operational costs.
Implementation Method 1
each of the at least one clay conduit(s) is provided with a conduit wall enclosing a conduit volume... enhances heat transfer by rotating conduits around an axis... direct heat exchange
Implementation Method 2
The rotation of the clay conduit during said cooling enhances the thermal energy transfer from the calcined clay via the conduit wall to the coolant in the coolant channel
Data Source
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AI summary
A calcined clay cooler 100 with a rotatably supported clay conduit having a clay conduit wall enclosing a clay conduit volume with an upstream clay inlet and a downstream clay outlet provides an improved coolant handling as well as reduced operating costs, if the clay conduit wall comprises at least one coolant channel with a channel wall enclosing a channel volume and defining a channel inlet and a channel outlet.