In recent years, cement companies have been paying increasing attention to cement temperature, and have begun experimenting with various cooling systems to cool the cement. In this process, differences in understanding and requirements regarding cement coolers have given rise to some related issues. We would like to discuss and analyze these issues with you here, in the hope of reaching a consensus.
The issue of temperature drop is a primary concern for many cement companies. Many companies focus solely on the extent of the temperature drop in cement while overlooking the underlying conditions. Practice has shown that the extent of the temperature drop is related to the following factors.
1. The volume of cement requiring cooling: All other conditions being equal, the larger the volume, the smaller the temperature drop. Therefore, to achieve the same temperature drop, a larger machine model is required.
2. The initial temperatures of the cement and the cooling water. Some customers simply insist that the cement cooler achieve a specific temperature reduction (e.g., 30°), without considering the initial temperatures of the cement and the cooling water. In practice, it has been found that the greater the temperature difference between the cement and the cooling water at the start, the greater the temperature reduction; conversely, the smaller the temperature difference, the smaller the reduction. Therefore, special attention must be paid to the heat dissipation of the cooling water. It is essential to ensure that the initial temperature of the cooling water remains at a low level; discussing the extent of cement temperature reduction without considering the initial temperatures of both the cement and the cooling water is unscientific.
3. Matching the Amount of Cement with the Volume of Cooling Water. Once the initial temperatures of the cement and cooling water have been determined, it is particularly important to match the volume of cooling water to the amount of cement. When the volume of cooling water is too small, the heat exchange capacity is insufficient, which affects the extent of cement cooling; conversely, when the volume of cooling water is too large, it results in a waste of resources and energy.
From the arrival of raw materials, through crushing, grinding, and calcination, to the grinding of clinker, companies are making every effort to reduce energy consumption at every stage in order to lower carbon emissions and production costs. Therefore, during the cement cooling process—which takes place before the cement leaves the plant—it is essential to pay close attention to electricity consumption. Failure to do so would render previous efforts futile and negatively impact the company’s production costs and overall competitiveness.
Cement production is a continuous assembly-line process, and problems at any stage can affect the overall operating rate of the production line. This requires that cement coolers, like other equipment, maintain a high operating rate to ensure the efficient operation of the cement grinding system.
Cement (water-cooled) coolers rely on the effective use of cooling water. There are two methods for supplying cooling water to the cooler: spray cooling (open-loop) and recirculating water (closed-loop). Due to the operating environment of the cooler, the water quality in an open-loop spray cooling system is prone to contamination. Additionally, the steam generated by the spray can impair visibility on-site and contribute to equipment corrosion. Therefore, a closed-loop recirculating water cooling system is the optimal choice.
The trend toward larger-scale cement equipment inevitably requires correspondingly larger coolers. However, due to limitations imposed by operating principles and equipment structure, scaling up coolers presents numerous challenges that must be overcome in order to meet the technical and equipment requirements of modern cement production.
The gasified, water-cooled, high-efficiency cement cooler developed by Shanxi Longzhou Conveying Machinery Co., Ltd. effectively resolves the above issues. Practical experience has shown that when the initial temperature of the cement entering the cooler is around 70°C and the inlet water temperature is below 30°C, the cooler can achieve a temperature reduction of more than 20°C; when the initial cement temperature is around 100°C and the cooling water inlet temperature is below 30°C, the temperature reduction can reach over 30°C; when the initial cement temperature is around 130°C and the cooling water inlet temperature is below 30°C, the temperature reduction can reach approximately 40°C. The comprehensive electricity consumption of the cooling water is less than 0.5 kWh, enabling continuous and stable operation with virtually zero energy consumption. The circulating water operates in a closed-loop system, eliminating concerns about environmental or water pollution; only anti-freeze and anti-scaling measures are required. The issue of scaling up equipment has also been effectively resolved. Since there are no moving parts, the equipment can be scaled up according to cooling capacity requirements, with only transportation and process layout considerations to address.
Currently, a single unit can produce over 400 metric tons. If customers have such a need, the equipment can be scaled up further without any issues regarding capacity or operational reliability.
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