POLYTRACK clinker cooler.

PolysiusA company ofThyssenKruppTechnologies

tk

New, unconventional solutions provide the basisfor the sophisticated clinker transport mech-

anism: the transport tracks are driven by hydraulic cylinders installed

underneath the static aerationfloor.

The variable strokespeeds of the transport

tracks cause an optimum trans-verse distribution of the clinker over

the entire width of the cooler, which evencompensates for non-central clinker dischargefrom the kiln and reliably prevents clinker fritting.

POLYTRACK the future-oriented clinker cooler from Polysius.

Only if you define what you need,do you have the chance to get what you want.

The wish list that Polysiuscompiled before starting withthe development of a newclinker cooler concentrated onthe requirements specified bythe market: x high-performancex compact x low-wear x flexibleapplication x favourably pricedand x easy to maintain.

And POLYTRACK, the result-ing new cooler generation, pro-vides a range of advantagesthat fully correspond to thehighly complex requirementprofile. Numerous innovativeprocess and design detailsmake the POLYTRACK afuture-oriented solution fromboth the mechanical and theprocess technological points of view.

POLYTRACK advantages at a glance

The POLYTRACK, a combi-nation of static, horizontal aeration floor and above-floortransporting system, offers on the basis of its extremelyefficient clinker transportingprinciple and strict separationof transportation and aerationfunctions the following com-pelling advantages: x ideal transverse distribution

of the clinker, resulting in uniform, efficient cooling of all grain size fractions over the entire width of thecooler,

x extremely low constructionheight,

x very high thermal efficiency,x a robust, low-wear and easy

to maintain construction, with resultant outstandingavailability and

x a consistent modular design.

The clinker transporting principle providing the push for success

The clinker transporting system a unique feature of this clinker cooler is extremely effective:

Above the static aeration floor, trans-port tracks are arranged in line withthe direction of clinker conveyance.The rows of transport tracks are posi-tioned a certain distance from eachother, with the aeration elements forblowing cooling air into the clinker bedlocated between them. The number oftransport track rows is determined bythe required width of the cooler. Everyrow of transport tracks runs the entirelength of the cooler.

To convey the clinker, the transporttracks move forward together andthen move backward individually.

By varying the transport stroke lengthand frequency the conveying speed of the clinker bed and thus the clinkerbed depth and clinker throughput are optimally controlled over the entirewidth of the cooler. Implemented for the first time in a clinker cooler,this solution provides the best pre-conditions for consistent and uniformcooling of all grain size fractions.

Intermediate crusher concept

Thanks to the highly effective clinkertransporting principle there is noneed for sloping cooler grates. Dueto its horizontal construction, thePOLYTRACK has an extremely lowoverall height. This results in enor-mous capital cost savings (for thecooler itself and, as a result, also forthe rotary kiln and preheater) andallows installation even under spaceconditions which hitherto ruled outthe placement of conventional cool-ers - e.g. in the case of plant con-versions. Even with limited installa-tion heights, it is possible to install aroll crusher as intermediate crusherand thus intensify the cooling.

Aeration concept

As the wear suffered by one compo-nent must not affect the efficiencyand throughput of the machine (anessential requirement of the market),the POLYTRACK was so designedthat the functions transporting theclinker bed and distributing thecooling air in the clinker bed arestrictly separated.

The air is distributed by static aeration elements that are locatedbetween the transport tracks. Largeboxes integrated into the aerationelements are permanently filled withclinker and thus provide autogenouswear protection. Thanks to theirdesign and robust construction, the transport tracks suffer minimalwear, and what wear occurs has no influence on the aeration of theclinker bed.

Sealing concept

Special, sliding element pairs reli-ably seal the few contact zonesbetween the static and the movingcooler components. As a result, noclinker can fall through the aerationfloor. This does away with the needfor wear-intensive grate riddlingsconveyors which is another crucialfactor in reducing the constructionheight.

Specially developed low-wear sliding elements reliably seal the few contact zones between the static and the movingcooler components.

The clinker is transported by the synchronised forwardmovement of all the transport tracks.

The air blast unitsinstalled between the

grate steps of the staticprimary grate enable

highly-effective eliminationof snowman at the

specific points where they form.

POLYTRACK hydraulic power unit.

The air is distributed via the labyrinth construction of the static aeration elements.

Clinker collects in the boxes andprovides autogenous wear

protection.

ThePOLYTRACK

has a modular designand can be configured without any

problem to provide a customised solutionwith a static primary grate and an intermediatecrusher.

Modular concept

Thanks to its modular design, the POLYTRACK

cooler is an extremely flexible solution forboth new plants and conversion retrofittings.The modules are 2.4 m and 4.8 m long and1.5 m/2.0 m and 2.5 m wide, so that appro-priate module combination permits straight-forward adaptation of the cooler length andwidth to different throughput rates.

The modules are preassembled in the manu-facturing shop. This ensures optimum align-ment of the clinker transport and aerationelements, thus saving a significant amountof work during assembly on the plant siteand providing the important benefit of shortinstallation, commissioning and in thecase of conversions plant stoppage times.

Completely preassembledPOLYTRACK modules in the

manufacturing shop.

The very compact construction of the cooler permits cost-effective retrofitting, even

under extreme space restrictions.