Cooler upgrade at Kaiser Cement Permanente Plant utilizing neoteric technology

Abstract

The development of a grate system which would improve air distribution in the critical first compartment area was a major improvement in the operating characteristics of a conventional reciprocating grate cooler. This technology became common in the mid 1980s with many new coolers and retrofits installed in subsequent years. The operational advantages, particularly for retrofit systems, is improved clinker production rate, better energy efficiency, and a reduced vent air requirement for a given clinker exit temperature. With such a list of major improvements, the justification to upgrade for a cement plant with cooler problems is easily seen. The clinker cooler retrofit project at Kaiser Cement's Permanente Plant was not based on the 'traditional' benefits of the new grate systems. The project justification was primarily based upon improved mechanical life hence reduced maintenance costs. Energy improvement was a minor consideration with no significant changes in clinker production rate expected. The results after one year of operation prove this premise to have been correct and the project payback will be achieved as expected.