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CYCLONECOOL™ - GAS COOLING IN TOP CYCLONES
Evaporative cooling is applied in certain places in a cement plant to cool hot gas before it is emitted to atmosphere due mainly to enviromental concerns. Cooling hot gas within particular limits and regulations always need precise monitoring systems as well as complicated gadgets which means capital and running cost. This was the main point of COOLING CONTROL® ENGINNEERS to contemplate deeply how to make beneficial results while gas cooling was creating natural costs within its system. Our Enginneers having extreme process knowledge and mentality of ‘’hot gas’’ in a cement plant have started to study in early 2000 to convert the cost to the gain. Thousands of engineering R&D hours came to a conclusion first on March 2003 with significant and excellent field application positive results. COOLING CONTROL® has subsequently accomplished several systems since 2003. 

 

The gas cooling in the top cyclone, CYCLONECOOL™, purely means great deal of energy saving or plant capacity increase or reduce of  recycling ratio in the line.

 

Cooling Control® CYCLONECOOL™ evaporative cooling systems are the latest technological invention of cooling at the top cyclone which enables approximately 200 - 250 KW/h or more energy saving in preheater fan, bag house fan, reverse air fan as well as fewer maintenance and less wear on working parts in respect to system parameters. The CYCLONECOOL™ also provides higher cyclone efficiency thereby higher production with a marginal investment, and mostly overcomes fan coating problems if available.
 
CYCLONECOOL™ - GAS COOLING IN TOP CYCLONES
In the Pre-heater Cyclone Water Spray System - CYCLONECOOL™, cooling water is injected close to the dipping tube against the gas flow in an absolute fine mist form to cool down the hot gas. While the high pressure water mist spray enables to condition/cool the hot gas, it also agglomerates the dust, parallelly permits and generates an exceptional outcome as better collection ratio in the cyclone in a superior or more excellent manner. 

    

The major advantages to cool the excessive gas temperature at to cyclone would be summarized as follows: 

 

*THE CYCLONE RETENTION EFFICIENCY INCREASES DUE TO THE FOG CURTAIN GENERATED BY THE WATER SPRAY AGAINST THE GAS FLOW, THUS IMPROVING THE COLLECTION. 

*DUST RETURN RATIO IN THE COMPLETE LINE DECREASES BY HIGHER EFFICIENCY AT TOP CYCLONE AFTER COOLING. 

*MORE GAS CAN BE HANDLED BY ID FAN WITH THE SAME KW DUE TO THE FACT THAT THE COOLED GAS OCCUPIES LESS VOLUME  OR, POWER SAVING IS POSSIBLE TO HANDLE THE SAME GAS VOLUME. 

*DUE TO THE COOLED GAS, IT IS POSSIBLE TO ELIMINATE FAN COATING AND VIBRATION PROBLEMS, THEREFORE KILN STOPPAGES WILL NOT BE AN ISSUE DUE TO COATING. 

*INCASE OF ID FAN IS BEFORE THE GCT, THERE IS A GREAT VALUE OF POWER SAVING IN IDLE TIMES OF ID FAN SUCH AS RM-OFF CONDITION. 

*THE USER CAN CHOOSE THE DESIRED TEMPERATURE REDUCTION, AND    SET ON THE PLC WITHIN THE CALCULATED DELTA T BY CHANGING THE SET POINTS WHICH GIVES A FLEXIBILITY TO THE SYSTEM OPERATION. 

 

COOLING CONTROL® generally utilize high pressure pumps with a Variable Frequency Drive (VFD) which propose to operate between frequency limit of 30-60 cycles so as to maintain the temperature drop of calculated delta oC under varying gas flow rates. Use of VFD permits precise control of power. Many of Cyclonecool™ systems for cyclone cooling are successfully operating in cement plants. The temperature variation in cyclones can be controlled well within the operating range of the VFD. 

    

The overall contol of whole system is conducted by PLC incorporating up-to-date technological advances where microprocessors enable incomparable control of the system, user friendly operation, reability, close loop control and managing almost all components automatically
CYCLONECOOL™ - GAS COOLING IN TOP CYCLONES
The gas cooling questionnaire is a guide to make fully detailed heat balance calculations. Please contact us to submit you the comprehensive questionnaire.


15
CYCLONECOOL
GAS COOLING IN TOP CYCLONES
TOWERCOOL
GAS COOLING IN GAS COOLING TOWERS
COOLERCOOL
GAS COOLING IN CLINKER COOLER BEDS
DUCTCOOL
GAS COOLING IN DOWNCOMER DUCTS
MILLCOOL
WATER INJECTION TO CEMENT MILLS
RAWCOOL
WATER INJECTION TO VERT. ROLLER MILLS

 
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