CRITICAL REVIEW OF PLANETARY COOLERS TECHNOLOGY

Lcio Barreto Pereira, lucio@ufmg.br Ricardo Campos de Freitas, rcfreitas@terra.com.br Rudolf Huebner, rudolf@ufmg.br
Universidade Federal de Minas Gerais Departamento de Engenharia Mecnica Campus Pampulha Av. Presidente Antnio Carlos, 6627 CEP 31270-901 Belo Horizonte MG - Brasil

Abstract. Planetary Clinker Coolers, installed at the outlet of the rotary kiln, have been widely used since 1920 in the manufacture of cement, and basically perform two tasks. The first is the heat recovery from the hot clinker leaving the kiln and the second is the cooling off clinker itself to allow appropriate handling. Three types of coolers are most used in the cement industry, the grate cooler, the rotary cooler and the planetary cooler. The planetary cooler, subject of the present article, works based on the same physical concepts used in ordinary rotary coolers. Typically, the cooling air enters the cooler in counter current with the hot clinker, lowering the clinker temperature and, at the same time, improving the performance of the combustion at the clinker kiln burner by means of pre-heating the secondary combustion air. Planetary coolers can be considered quite simple equipment since they are attached to the outlet of the rotary kiln, without separate drive, and do not require de-dusting, usually used in other types of clinker coolers. However, some disadvantages have to be considered also: poor control of cooling air volume since it depends on the kiln combustion requirements; does not allow use of tertiary hot air for combustion in the pre-calciner, which has proved of great benefit in high-efficiency kilns; it is difficult to maintain the even distribution of the hot clinker through each pipe; special care is necessary during the structural design of the kiln shell due to high loads transmitted to the kiln. Although widely studied in the past, today there have been no large studies to improve the planetary cooler efficiency. However, the quantity of existing planetary coolers still in operation is very large and the cost for replacement for a more efficient kind of cooler often makes the investment unfeasible. This paper proposes to present a review of planetary cooler mathematical modeling used to design this equipment in the past. This review study will provide the fundamentals to evaluate possibilities of modeling the equipment using new techniques such as Computational Fluid Dynamics (CFD) with regard to improve the thermal efficiency in clinker burning plants. Keywords: planetary clinker cooler; cooling; rotary kiln; energy recovery; mathematical models 1. INTRODUCTION Portland cement is produced from a carefully proportioned mixture of minerals containing, mainly, calcium (typical limestone), silica (clay and sand), alumina (clay and shale), and iron (iron ore). After proportioned and grounded to a fine powder, the raw feed material (raw meal) is fed to the rotary kiln to posterior pyro-processing. The product of pyroprocessing is the clinker and it is grounded in a grinding mill station to meet the criteria of fineness, composition, setting time, etc. Rotary cement kilns are operated in a cross-current configuration, with the hot gas flowing in the opposite direction of the material, resulting in a better thermal efficiency. Basically, cement kilns consists of 03 main components which are the Pre-Heater, the Rotary Kiln and the Clinker Cooler. The Pre-heater, usually in the form of cyclone tower, is attached to the feed side of the rotary kiln, where dehydration and calcination of the raw meal occur. The Rotary kiln is placed immediately after the pre-heater tower. The calcined material leaving the pre-heater tower is fed into the kiln where further chemical reactions occur to form the clinker. The Clinker cooler is situated immediately after the rotary kiln and is the place where the residual heat content of the clinker is transferred to the secondary combustion air, improving the thermal efficiency of the kiln, and, at the same time, cooling off the clinker for easy handling. The kiln slope (3 to 4 - angle between the rotary kiln center line and the horizontal) causes the material to move toward the material outlet of the kiln. Fine grounded coal, usually fired at both rotary kiln and pre-heater, provides the necessary thermal input to allow pyro-processing to occur. The cooled clinker, product of solidification of melting clinker at the clinker cooler, consists of grey colored nodules, ranging from sand like grains up to 50mm diameter, depending on the chemical composition and process variables. The clinker leaves the kiln at 1400C (F.L.Smidth, [1980?]), and falls into the clinker cooler, where the heat recuperation starts. Cold clinker, after being proportioned with gypsum and minerals component (pozolana, blast furnace slag, silica, iron ore and carbonated material), is fine grounded to produce different types of cement, depending on chemical configuration and process parameters.

2. CLINKER COOLERS The process of cooling influences the structure, composition and grindability of the clinker, directly affecting the quality of the resulting cement. The rapid cooling of the clinker minimizes the formation of glass phase and the size of magnesium oxide crystals, ensuring maximum yield of alite (tricalcium silicate), therefore resulting in a more sound cement. Cooling off clinker, besides allowing clinker to be more easily handled and stored, improves the efficiency of the rotary kiln both by recovering the residual heat from hot clinker and adding performance at the kiln burner heating secondary combustion air. Three types of coolers are most used in the cement industry, which are the grate cooler, the rotary cooler and the planetary cooler. In this work the focus is on Planetary Coolers because they are still widely used in Brazil. Planetary Coolers, also known as Satellite Coolers, work based on the same physical concepts used in ordinary rotary coolers. The hot clinker enters the cooler at approximately 1.400C, at the rotary kiln outlet and, after exchanging heat with the cooling air, leaves the cooler at 150 350 C. The cooling air enters the clinker cooler in counter current with the hot clinker, exchanging heat with it, therefore, improving the efficiency of the combustion at the kiln burner by means of pre heating the secondary air. Figure 1 presents a typical rotary cement kiln with planetary clinker cooler. It consists of 9 to 11 steel cylinders arranged around the circumference of the discharge end of the kiln, forming an integral part of the rotary kiln. The satellites revolve together with the rotary kiln (1 to 3 rpm), without a separate drive. Each tube is partially lined with refractory bricks, up to about 50% of its length. The remainder of the tube length is designed without lining to allow heat transfer between the external wall and the ambient air.

Pre-Heater

Planetary Cooler Kiln

Figure 1 Typical rotary cement kiln with planetary clinker cooler The heat transfer is based upon cascading the clinker through the cooling air, during each revolution of the kiln. To improve the heat transfer efficiency, each cylinder is provided with internal buckets and scoops, to better expose the clinker to the cooling air. The design and positioning of the scoops has a significant effect on heat transfer between the clinker cascading transversally inside the tube and the cooling air flowing along the tube. The cooling air, after exchanging heat with the hot clinker, enters the rotary kiln as secondary combustion air, therefore improving the combustion efficiency. Typically, the heat transfer occurs between the hot clinker bed inside the cooler, the internal and external shell surface areas, the clinker falling inside the cooler, the secondary air and the surroundings. Table 1 presents typical operational data usually found in planetary coolers Table 1. Operational Data in Planetary Coolers. Kg of air / kg of clinker [kg/kg] (2) 0,8 1,3
(1)

Clinker temperature (1) at cooler outlet C 350-160

Power consumption (2) [kW] 0,8

Thermal efficiency (2) [%] 67

L/D (2)

Retention time (1) [min] 10....45

Specific volume (2) [m3/t 24 hour] 0,125....0,600

10....12:1

: Duda (1977); (2) Ludera and Poland (1980);

Many factors affect the recuperation efficiency inside the clinker cooler. Particle size distribution (PSD), for instance, affects the heat transfer between falling clinker and cooling air inside the cooler. In principle, coarse clinker requires more cascading than fine clinker. Excessive cascading, therefore finer PSD, has proved to lead to overfilling the coolers and backspilling into the kiln, resulting in higher clinker exit temperature (less efficiency). Other important factors as the type and

distribution of refractory linings, type and distribution of scoops and buckets and recirculation phenomena, also play an important role on efficiency of satellite coolers. The diagram in the Figure 2 shows a typical temperature distribution along the planetary cooler. The clinker temperature at the inlet (hot side) of the cooler is in the range of 1100 to 1400C, while temperatures ranging from 120 to 350 C can be expected at clinker outlet (cool side). The cooling air enters the cooler at ambient temperature and, after exchanging heat with the hot clinker, reaches 650 to 800 C. The residence time inside the cooler is, approximately, 10 to 40 minutes, pressure drop is about 20 to 40 mmWG and velocities of about 0.5 to 1.2 m/s are to be expected to the cooling air (Ludera and Poland, 1980).

Figure 2 Typical temperature distribution along the planetary cooler (adapted from Steinbach, 1987) Planetary coolers can be considered quite simple equipments because they do not have a separate drive since they are attached to the outlet of the rotary kiln, and do not require de-dusting, usually used in other types of clinker coolers. However, some disadvantages have to be considered also (ALSOP et al, 2001): poor control of cooling air volume since it depends on the kiln combustion requirements; does not allow use of tertiary hot air for combustion in the pre-calciner, which has proved of great benefit in high-efficiency kilns; it is difficult to maintain the even distribution of the hot clinker through each pipe; special care is necessary during the structural design of the kiln shell due to high loads transmitted to the kiln. Other problems associated are the defective design of kiln elbows allowing material fall-back into the kiln; the short service life of refractory lining and noise emission. Different process characteristics may influence the performance of the planetary coolers. Heidelberg (1977) performed temperature measurements installing infrared television apparatus and thermocouples in several zones at the planetary cooler and mentioned some characteristics as the best cooling efficiency was achieved with clinker of approximately 6 mm average particle size; no ascertainable increase in heat consumption of the kiln when up to 30g of water per kg of clinker was injected; no effect of rotational speed was detectable within the range from 2 to 2.3 rpm; the overall clinker output from the kiln can, even for constant meal feed rate and unvarying kiln speed, have variations of as much as +50% as a result of coating detachment or raw material influences. Kreft and Ennigerloh (1988) evaluated, by experimental analysis, different type of lifting elements to determine the scattering effect achieved during the course of one revolution of the scoops and to optimize the number and arrangement of the scoops with a view to obtaining the highest possible density of the curtain of falling clinker in the cooling space. With the objective to permit passage of a normal size of products to the cooler, avoiding big amount of material that could break the lifters, or could plug the cooler and render it inoperable, Miller and Luepke (2002) suggested a toothed grate in the opening connection between the kiln and the planetary cooler. Deussner (1975), Brachthauser and Langmaack (1974), and

Deussner and Fleischer (1976) proposed different solutions to cool the material using injection of water in the planetary cooler. 3. MATHEMATICAL MODEL OF PLANETARY CLINKER COOLERS Mathematical models have been presented by different authors mainly to fulfill two purposes: on one hand, to analyze the influence of certain process parameters without the necessity of expensive experiments and, on the other hand, to estimate value of parameters that cannot be measured with the techniques available, such as the temperature distribution inside the cooler. The approaches proposed by Carlson and Fernvik (1974), Ludera and Poland (1980), Vogel and Winter (1980) and Steinbach (1987) to model planetary and rotary clinker coolers, will be described in the following lines. 3.1. Carlson and Fernvik (1974)

These authors proposed a mathematical model to evaluate the heat transfer between clinker and the secondary air in the planetary cooler. Temperature measurements of the secondary air and the clinker confirmed the validity of the mathematical model. Simulations were performed to estimate the behavior of different process variables. The cooler was divided into several discrete intervals of 0.5 m, following the clinker pass inside the cooler. At each discrete interval, from the clinker inlet to outlet, energy balances were performed sequentially at each section, starting with known parameters such as clinker and cooling air temperatures at clinker inlet (hot side). Heat transfer between bed material inside the planetary cooler, the internal surface of the cooler shell, the material cascading from the scoops, the external surface of the cooler shell, surroundings and the secondary (cooling) air were mathematically modeled by empirical equations as listed below. Air and clinker temperatures resulting from the sequential heat balances were compared with known parameters at the clinker outlet (cold side of the cooler). Provided sensible differences were met, the calculation would be repeated based on different parameters until a match was found. The heat transfer between both the surface of the bed material (hot clinker) and internal surface of the kiln shell with the cooling air was mathematically modeled using the empirical equation:

Nu = 0 ,024. Re0 ,8 . Pr 0 ,37

(1)

The convective heat exchange between falling clinker and the air was modeled as a free fall sphere with a transversal forced air flow. Nusselt number Nu was estimated as indicated below, considering Reynolds in the range of

10 < Re < 10 4 .
Nu = 2 + 0 ,53. Pr 0 ,33 . Re( 0 ,5+0 ,002. Re
0 ,25

(2)

The temperature of the clinker spheres were modeled by Fouriers differential equation of heat conduction:

T 2T T = b 2 + f(x) t x x

(3)

The function f (x ) was defined to a free fall spheres surrounded by a flowing medium as f (x ) = 2 / x and the constant

b was defined by the equation

b=

.c

(4)

where , and c are the thermal conductivity, specific gravity and specific heat content of the clinker, respectively. Temperature profiles ( T ) of the clinker falling grains as function of time ( t ) were plotted to different falling angles. The program uses the temperature profiles to integrate the total heat transferred to the cooling air flow. Thermal conductivity for the clinker and other properties of the clinker and the air where taken from literature or from laboratory experiments.

The clinker temperatures inside the cooler were measured with thermocouples attached to the kiln shell. The thermocouples were placed inside the buckets to increase the contact time between element and hot clinker. Repeated calculations with new adopted temperatures were required before a match between calculated and measured temperatures were reached. Data recorded from the thermocouples showed good agreement with calculated temperatures. After adjusting the model to the known parameters (inlet clinker temperature and cooling air inlet temperatures), several simulations were performed using the mathematical model to estimate the response of the clinker cooler. Changes in the clinker inlet temperature, fluctuations on cooling air quantities, reduction of ceramics zones, uneven material feed and changes in the number of scoops were simulated by varying the inlet parameters. Several types of construction, location and quantities of scoops were simulated. The model demonstrated that the majority of the heat exchange occurs between cooling air and the material falling from the lifter scoops. 3.2. Ludera and Poland (1980)

In determining the heat engineering characteristics of planetary coolers, the authors proposed a more empirical calculation approach. Based on dimensions and throughputs tabulated from 38 existing satellite coolers, the following formulas were derived for determining the tube diameter Eq. (5), tube length Eq. (6), effective volume Eq. (7), specific volume Eq. (8), thermal rating Eq. (9) and heat absorbed by secondary air Eq. (10).

& Dch = 1,019.m K 0 ,3156 [m]

(5) (6) (7) (8) (9) (10)

& Lch = 4 ,614.m K 0 ,6516 [m]

& Vch = 3,76.mK 1,282 [m3]

vCS = 0,0732.Lch 0 ,5299 [m3/t 24 h]

Qch = 0 ,3084.Dch 2 ,98 [Gcal/h]

QL = 0.80.Qch [Gcal/h]

& where mK is the mass flow of the clinker in t/h. As a result, based on the application of the Dimensional Design Method described above, geometric dimensions of planetary coolers can be estimated based on throughput of the clinker cooler.
3.3. Vogel and Winter (1980)

In this case, the authors presented a closed-form solution of the heat transfer equations, with loss items, and indicate the significant effect on the clinker and air temperature behavior in the cooler. Based on a general heat balance to a counter-current rotary cooler:
& m K .c K .( dTK ) = .dA0 .(TK TL ) + k .dA2 .(TK TU )

(11)

and
& m L .c L .(dTL ) = .( dA0 )(TK TL ) .

(12)

where

the indices K means clinker, L means air and U means surroundings; & m means mass flow [t/h]; T means temperature; and k means, respectively, heat transfer and complex heat transmission coefficients; c denotes the specific thermal capacity;

A0 is the heat transfer surface area of the clinker participating in the cooling process and A2 is the wall
surface area. 1st and 2nd terms in the right hand side of Eq. (11), respectively represent the heat transfer by clinker to the air and heat loss to the surroundings;

the authors derived a system of two linked differential equations to describe the cooling process.
.A0 k .A2 .A0 k .A2 dTK = W + W .TK + W TL + W .TU & & & & x K K K K d L and & .A0 W K dTL = . .(TK TL ) & & WK WL x d L

(13)

(14)

With x representing small element in length of the cooler L . Using temperature in dimensionless notation, and considering TU = TL , the authors derived the functional relation of the dimensionless arguments of the system, C , and , as described below.

C describes the ratio of the two thermal capacity flows of the clinker ( K ) and the air ( L );
C = &K W
L

& W

(15)

characterizes the heat transfer from the clinker to the air flow; .A = & 0 W
K

(16)

characterizes the heat transmission from the clinker to the wall of the cooler, the heat transfer through this wall, and the heat transmission from the wall to the surroundings. = & W
k .A2
K

(17)

Thus, it emerges that dimensionless clinker temperature and air temperature are characterized by the dimensionless arguments C , and , as described above. If one of them is known, the other can be calculated. The evaluation of equations proposed makes it possible to perform fairly reliably calculation of the exit temperatures, provided that reliable information on the dimensionless arguments C , and is available. Based on an investigation on 14 existing planetary and rotary coolers and, following the mathematical approach described in the preceding section, the dimensionless arguments of the differential equations were calculated to each cooler. From the analysis of the data tabulated to the 14 coolers, emerges that the dimensionless arguments are within the ranges 0.72< C <0.96; 1.3< <3.4; 0.14< <0.60, and that the difference between calculated and measured clinker exit temperatures, using the mathematical approach described herewith, are in the range of 10%. Thou, the thermal data of a selected rotary cooler can be accessed if compared with the values tabulated to the 14 coolers and it is possible to draw inferences as to the further development of the design features of an existing cooler. 3.4. Steinbach (1987)

Steinbach (1987) presented a mathematical model for theoretical investigations on rotary coolers. The model is also applicable to planetary coolers, since new equations for convective and radiant heat losses to the surroundings are available.

The following assumptions were proposed by the author: steady state; temperature constant within a section; heat transfer (convection and radiation) is zero in the axial direction; temperature of the air and dust are the same; dust do not settle in inside the cooler; The following nomenclature were used to describe mathematically the heat transfer phenomena: for connective heat & & transfer; for radiation, for conduction, T for temperature, Q for heat transfer flow, H for the enthalpy . The
K

subscripts indicate K for clinker; L for air; S for dust; W for wall; U for surroundings. Subscript letters denotes origin and destiny respectively and superscript letters indicate the type of heat transfer. In this model, the cooler was divided into 100 sections along the axial direction. To each separate section, energy balances were performed to the four process variables: clinker, air/dust, internal surface of tube, external surface of the tube. The calculation starts at the clinker inlet, where the temperature of the external surface of the tube is varied until the balance leaves no reminder. Following in the direction of the clinker flow leads to the clinker and air temperatures at the boundary of the next section. The process is repeated until the last section, were the entry temperature of the air is found. The whole procedure is repeated until the initial assumptions are confirmed. For each section, the energy balances were represented by the equations (18), (19), (20) and (21) below. The equations are defined between 2 planes x and x + x as below. In sequence its presented the equations regarding radiation and convection inside the tube, convection at external surface and conduction through the wall. A zone with incoming and outgoing heat and enthalpy flows is shown in Figure 3. 3.4.1. Clinker enthalpy balance To balance the clinker enthalpy at the each unit section, the following formulae was presented:
& & & & &x &x & H K H K+ x H S Q KW Q KL Q KS Q KW = 0

(18)

To the balance air/dust enthalpy at each unit section, the following formula was presented:
& & & &x &x & H L + x H L + H S + QWL + Q KS QWS = 0

(19)

To the balance heat exchange inside the tube at each unit section, the following formula was presented:
& & & & & QKW + QKW QWL QWS QWW = 0

(20)

And to the balance heat exchange outside the tube at each unit section, the following formula was proposed:
& & , QWW QWU = 0

(21)

Since specific enthalpy of clinker and air are temperature dependent, special care must be taken.

Figure 3 Symbols and convections used by the Steinbach in the model

3.4.2. Radiation inside the tube Similarly, for each section, the energy balance due to radiation can be expressed as below (temperatures T in C)
& Q KS = KS .A3 . . K . S . (TK + 273 ,15 )4 (TS + 273,15 )4 & QWS = WS
4 4 4 W S W S

& Q KW = KW

[ ] .A . . . .[(T + 273,15 ) (T + 273,15 ) ] .A . . . .[(T + 273,15 ) (T + 273,15 ) ]

4 4 5 K W K W

(22) (23) (24)

denotes the irradiation coefficient. The emissivity values for clinker and steel have been taken as 0.9. is the
Stefan Boltzman constant. The coefficients Ai represent the irradiant area. 3.4.3. Convective flow inside the tube The equations below applies for convective heat flows.
& QKW = KW .A6 .(TK TW ) & QWL = WL .A8 .(TW TL ) & Q KL = KL .A7 .(TK TL )

(25) (26) (27)

with the coefficients Ai representing the convective transfer area. By the reference from Steinbach (1987), a value of 120 W/m to the convective heat transfer coefficient between clinker and the wall, KW , can be considered for relatively large particles. Conventional heat transfer coefficients between clinker and air KL and between wall and air WL can be used. The clinker remaining in the bottom of the rotating tube can be modeled as a flap plate and the clinker that falls from the clinker lifters inside the rotating tube can be conceived as free fall spheres surrounded by a flowing medium. Particle size distribution can be approximated by uniformly sized spherical particles distributed according to the particle fractions obtained from RRSB distribution. To determine the number of spherical particles to each fraction, it is necessary to know the retention time of the clinker inside the cooler. According to Duda (1977), the equation below fits, where L is the length of the cooler, D is its diameter, p its inclination in degree, and n its rotational speed in rpm.
t= 21,24.L p .D.n

(28)

3.4.4. Convection through the external surface of the tube The heat transferred from the outside of the wall of the cooler to the surrounding (ambient air) comprises a convective part and a radiation part. It can be approximately calculated from equation below,
& , QWU = WU . .Da .x.(TWE TU )

(29)

where TWE is the external temperature of the wall and, the convection coefficient can be conceived as

WU = 0 ,3.Da + 9 ,25.4 ,9.

TWE T T + 0 ,14. WE + 0 ,078. WE 100 100 100

(30)

3.4.5. Conduction through the walls The heat transmission through the wall can be calculated from
& QWW = k .AC .(TWI TWE )

(31)

with the subscripts WI and WE denoting the internal and external characteristics of the wall respectively, AC representing the conduction transfer area, and
k .AC = 2.W . .e ln(DWE DWI )

(32)

with e denoting the thickness of the wall. For n layers of the wall the total k .A factor can be calculated by
1 1 1 = + ... + (k .AC )n k .AC (k .AC )1 (33)

4. CONCLUSION
Despite the frequent substitution of the planetary coolers by different types of equipment, mainly grate coolers, the quantity of equipments still in operation justify the analysis of this equipment using more modern and robust techniques. The formulations presented by the authors represent integral equations at the domain. Carlson and Fernvik (1974) and Steinbach (1987) proposed models discretizing the equipment and evaluating the heat transfer at each step. Ludera and Poland (1980) presented an empiric model based on installed equipments. With the equations of Vogel and Winter (1980) is possible to evaluate the planetary cooler considering three independents variables. Besides the models presented were performed under strict mathematical approach, additional points could to be considered to improve the assessment of thermal efficiency. In both models based on heat balance (Carlson and Fernvik, 1974 and Steinbach, 1987), Thermo-Imaging of the external cooler shell could add relevant information to the convection process between cooler and the surroundings. The recirculation phenomena of the clinker inside the cooler, specially the powder draw back into the rotary kiln, should be considered during the heat balance. Air velocity profiles and turbulence inside the cooler, resulting in a more accurate estimate of heat transfer between clinker and air, could be better modeled through the use of Computational Fluid Dynamics. The particle size distribution (PSD) of the clinker is an important factor in the assessment of heat efficiency. Each cement kiln produces clinker with different PSD and different physical characteristics, depending on raw material composition and process parameters. The authors modeled the clinker as spheres ranging from 6,3 mm to 30,0 mm without references to the sand like fraction of the clinker. In special, heat transfer between sand like fraction and clinker spheres inside the clinker bed should be considered. Additionally, size reduction of clinker particle inside the cooler should be considered. The design and location of internal fittings deserves special attention to improve the thermal efficiency. The use of new refractory and heat resistant materials, high efficiency scoops and the efficient distribution of fittings and insulation inside the cooler can improve thermal efficiency. Several techniques presented to other processes can be proposed, as modeling based on discrete particle method (Geng et al, 2009 and Yang et al, 2008), residence time of the material in the equipment (Chen et al, 2009), evaluation of the depth profile of the solid bed (Liu et al, 2009), modeling techniques by computational fluid dynamics to evaluate the external heat transfer with different conditions from the outside of the cooler and the region near the cooler in the inner side. So these techniques can be used to evaluate the internal heat transfer using the coefficients suggested by the authors and mentioned in this paper.

5. ACKNOWLEDGEMENTS
The authors are grateful to Walter R. Hunter, managing director of HUNTER Consulting Ltd., for the support during the execution of this work.

6. REFERENCES
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7. RESPONSIBILITY NOTICE
The authors are the only responsible for the printed material included in this paper.