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The Mardin Cement 4000tpd clinker cooler retrofit - breaking a new world record with the FONS Delta Cooler: Mogens Fons, Fons Technology International (Turkey)

Filmed at Cemtech Asia 2015, 21-24 June, Grand Hyatt, Bangkok, Thailand

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Okay, I'll show a presentation, and a small animation, and three and a half minute video that will give you a full picture of our cooler and then hopefully we'll have a few minutes for questions. Normally I say that, "Brilliant solutions spring from the well to go beyond the limits of what we imagine is technically possible" and we'll come to this phrase a couple of time during this presentation.

We always hear you see a complete cooler, it's a shorter flow cooler, which by the way, patented in 1999 as the first user of this technology, this one has eight lanes from our workshop where we check testfully with our hydraulic station and everything before we ship to the site, to break this record of stoppage time at the plant for a retrofit job.

We've a modular design. That means that each of our module is two meter long, you can see it down to the right and 400 millimeter is the width of our lanes. We actually store cooler for 10,000 ton per day in our stock, so we can either sell two 5,000 ton or five 2,000 ton with very short delivery time, because you can see the modular design to the left here, we just take the modules in with direction according to how wide is the cooler, how is the existing casing, and then the lengths to give us enough area for the aeration of our material.

Here you see the principle, all lanes go forward together and then every third goes back, and another every third and the last third. That means, when they retract, the two neighbors are not moving and this will give you the full transport, this is the highest transport efficiency of a cooler principle, and mark this is going horizontal. So that means the risk of Red River is hardly is reduced to near to zero. Some of the old reciprocative great coolers need to be on a slope to have enough transport efficiency.

We have more than 70% transport efficiency which means that our movable parts are moving very slow compared to the clinker pit, 70â„… our stroke length forward, back, back, back and then the clinker is moved than 70% of this 300 millimeter. This also save electrical consumption on the hydraulic system to move the lanes. And here, you see the lanes up to the right and if we take a cut in one of our lanes, which's done down here,

you can actually see that we've stationary, it's not keeping, we've stationery clinker. So that means that the blue one, not moving. They move together with lanes like a pocket, so grate plate is no more a wear item. We never change grate plate. The only wear part is the top of this small vertical plate between two grate plates and that has a 3 millimeter wear welding.

But that clinker serves both to protect the grates from heat and wear. Imagine cement in Turkey, this is Oyak group, the biggest producer in Turkey, we installed a 4,000 ton per day. So basically, we take out the old cooler to the picture on the left and leave us with the picture to the right where all internals are taken out. Then, we cover the hoppers because in this cooler concept, we have zero fall through of material so you don't have any more maintenance on your conveying system below the cooler.

Here, you can see that we cover the plates, they can remove the hoppers afterwards, we shorten the time only to put a plate and welt on the floor in our under grate compartment. To the right, it's done. Then, we bring in all our units which are two meter long. You can see them up to the right, this is how they leave our workshop and actually to the left we can push them in like that.

So everything is pre assembled, only the lanes have to be connected for every two meter with positioning pins and bolts, and after that is done, we erect the grate line to the left. You can see that the lanes are bolted together and then it takes one day to put in all our grates plates which you can see to the right ,and the seals, the seals between the lanes, right?

Of course, we put our hydraulic. There's one hydraulic cylinder per lane, for smaller coolers and for bigger coolers, two cylinders, but only one proportion valve. So, the two cylinders are hooked up in parallel just helping each other to distribute the load. Of course, the pipeline is done before hand to break this world record. This one we did actually in 21 days from flame off to flame on including the factory work. Direction

was like 14 day and OYAK group, after we've installed this cooler, only the cooler, they increase the production by 12% because a good cooler gives you a high temperature back to the kiln, with a high temperature going back to the kiln, already the air is pre-heated and we can lower the fuel consumption.

And then you can either make it into an increase of production because now your air flow is less, right? Because we've now more to suck through out pre-heater and our ID fan, and actually after we change this cooler, I think it was in the following weeks, the OYAK group gave two more orders to other plants, so quite impressive.

Now, a little bit of fear with the heat recuperation, let us think that this is the clinker layer, and it will vary a little bit in height. Sometimes the kiln gives more or less, so this is why I tried to show to you that if there's less clinker, more air will go, and if there's more clinker to the left, not so much air will go right.

And actually, then we will not cool the left part, and the right part will be cooled a lot. So it's not homogeneously cooled. Many of the competitors they made a pressure loss in the grate plate to somehow even the air flow, but we have made another one which is we call the STAFF, which stands for Steep Air Flow Function, you will see an animation in a minute, but actually there is a spring loaded shaft, flap here that can tilt into different positions.

If it closes, then it gives more air for the, reduce the area for the air to go, but I will show you an animation here in a short while, and it will be more clear for you. But, remember that it's a constant airflow. Here, I show some constant that means if the change to resist in the clinker layer still the same flow amount is the same.

So if we have full resistance in our clinker layer, then our staff, our flow regulator is not giving pressure loss. Only if the the resistance goes less in the clinker layer, the flaps start to close and give resistance. Which means that we can lower the compartment pressure, it's actually a win, win.

We can save electrical consumption for our fans since we have a lower compartment pressure and we can get a better heat recuperation. Here, since we have no fall through in our cooler, we can actually go under the cooler during operation. Even operational people don't need to know, we don't need to tell them to stop the fan, because we can actually, we have a Double Door Sluice system.

So, you go into that small compartment and close one door behind you, you don't need any tool, and then you pressurize opening a small valve here. I'm sorry, we didn't have time to find a better model. Then you pressurize yourself and once the pressure is the same, you can go in the cooler. So, even up in the CCR, they will not see the pressure dropping because you never ask the flow to go down.

Doing my many, many years in the cement industry, I have found out you can read, write a lot of volumes about maintenance. Every month you should do that, every two weeks you should do that, this, that, but honestly, if you don't make it easy, it will not get done. People don't do it, right? So first of all, you have to make it easy to go under the cooler and see, ah, my cylinders are doing fine.

Actually, we can have a cup of tea under the cooler because there is zero fall through, no clinker. Only, you need air protection because of the noise from the fan, right? The pressure maybe a 500 millimeter, water-gauge is the same as being in a swimming pool, half meter water, we can all do that.

So, both for new coolers and for retrofit, like two weeks for the smaller ones, no fall through of clinker. For new lines, we can reduce the complete kiln because the bottom of the cooler, the transport is normally zero, right? Now we don't have any track change, so for new plants we can lower the cooler, we can lower the kiln, we can lower the pre-heater. It's a lot of money and we can save electricity and kilo calories to change the cooler.

Normally we've a payback time of something like two years maximum for saving and you have no one wants to stop it, because now your grate plates are not wearing out, so we can capitalize, they save in fuel, they save in electricity. No one wants to stop it and spare parts. Our spare parts are less than 10% of our competitors. Actually, I showed to that top of that [incomprehensible] that you need to weld, this is basically it, and then every year, you change the steels in your hydraulic cylinders so that they don't leak.

Yes, and then comes here you can lower the voice, take the volume away. So here I'm standing with a smaller cooler, we have it also on our stand on top of the big cooler, this is a six lane cooler and we put some plastic. So here you can see on the forward slope, the clinker follows, on the return slope the clinker is not carried back to the fixed inlet. See here from the side, if you look up here, the clinker is not reflected back, but on the forward, they go together, this is the high transport efficiency.

So now you understand the working flow principle or circuit flow. Here you see in our workshop, this is a eight lane cooler, forward together and when it is eight lane, then three goes back, and three goes back and the two goes back, because it has to be totally eight here from the side with the hydraulic, with the PLC that controls the motion of our lanes.

Actually the first six meters of the lanes are stainless steel, the rest is mild steel, five millimeter bended plates. Normally, when we erect the new cooler, I signed a $100 bill together with the bank manager, and we put the money down in a grate plate and cover with clinker. And 11 months later, if there's no power failure you can pick up that $100 and I will double.

Again, you see here our very special bearing system. All mechanical engineers like this because this is a way to produce a linear motion using points of rotation, and what is so genius about this, the point of rotation can be sealed like the front wheel of your motorcycle, that's a point of rotation, so you can have a regular seal.

And now we've created a straight line motion using points of rotation and here you can see that we get automatically grease 0.2 CC of grease for each bearing every week. Up here you can see the flow regulator. So by having this trial in our workshop, we know that everything is ready to make a world record when we install the cooler. Here you see the flow regulator, it has the possibility, it's shown upside down. We can change the width of the gap and then the constant is a higher constant.

It's still a constant air flow regulator. A constant air flow disregarding of the resistance, but we can change the constant. We can go through upper doors and we can set the flow, especially up at the fix end, it's very important to make sure that the clinker is rightly distributed, and you can stop this one, and then you can start the animation. Yes, press there.

This is actually how it works our stacks. You can think about it like we have a certain pressure in our compartment. Let us call this 100, then if we have a full clinker layer up here, it maybe we have 80 in pressure loss. Up here on top, we have zero, so then 100 in the compartment, 80 in the clinker layer, then there will be 20, will be the delta pressure over the regulator, and this 20 is the one to flip the spring loaded flap into a new position.

So now you can see there is less pressure loss, and then of course, when there is less pressure loss up in the clinker pit then there will be a higher pressure loss over the device, because the two pressure loss is added together, have to get the compartment pressure to 100. And once it closes, then there is less area for the air to go, right?

It's very, like I said, brilliant solution because we work with mother nature, there's no electricity, there is no X-rays and no magic. Only the spring that automatically close if required. If not required, if the layer have the right resistance, it is fully opened like you will see what happened now. Now, it's fully opened and then there's hardly no resistance.

So we can lower the compartment pressures like I said before and save kilowatt hours.

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