Technical Field
[0001] The present invention relates to a cooling unit of a cooler apparatus configured
to cool high-temperature granular conveyed substances, such as granular cement clinkers,
while conveying the granular conveyed substances.
Background Art
[0002] A cement plant is provided with a cooler that conveys high-temperature cement clinkers,
produced through preheating, calcinating, and sintering, while cooling the cement
clinkers. One example of the cooler is a cooler described in PTL 1. The cooler includes
a plurality of cooling lattices and is assembled by arranging the cooling lattices
in a vertical direction. Each of the cooling lattices includes a plurality of V-shaped
profiles and is configured such that the V-shaped profiles are spaced apart in mirror
symmetry and offset to one another. Leg portions of the adjacent V-shaped profiles
are arranged with a gap therebetween, and the gap constitutes a labyrinth through
which cooling air flows. The high-temperature cement clinkers are placed on the cooling
lattices configured as above, and the cement clinkers can be conveyed while being
cooled by the supply of the cooling air through the labyrinths.
Citation List
Patent Literature
[0003] PTL 1: Japanese Laid-Open Patent Application Publication No.
2007-515365
Summary of Invention
Technical Problem
[0004] In the cooler described in PTL 1, the labyrinths are formed at the cooling lattices,
and the cooling air is supplied through the labyrinths, so that the cement clinkers
are prevented from falling down. However, since the labyrinths are formed at the cooling
lattices, all the cement clinkers cannot be prevented from falling down, and finely-granular
cement clinkers may fall down through the labyrinths. To prevent the finely-granular
cement clinkers from falling down, a passage area of the labyrinth may be reduced.
However, if the passage area of the labyrinth is reduced, a passage pressure loss
of the cooling air increases. The passage pressure loss of the cooling grate is preferably
about 30% of a layer pressure loss. If the passage pressure loss of the cooling grate
becomes higher than about 30% of the layer pressure loss, the electric power consumption
uneconomically increases.
[0005] Here, an object of the present invention is to provide a cooling unit capable of
uniformly cooling granular substances to be conveyed and also capable of preventing
not only large granular substances but also finely-granular substances from falling
down, and a cooler apparatus including the cooling unit.
Solution to Problem
[0006] A cooling unit of the present invention is included in a cooler apparatus configured
to cool high-temperature granular conveyed substances while conveying the granular
conveyed substances, the cooling unit including: a supporting member including a bottom
plate and configured to support the granular conveyed substances via a dead layer,
the dead layer being formed by depositing on the bottom plate granular embedded substances
lower in temperature than the granular conveyed substances; and diffuser tubes provided
at such positions as to be embedded in the dead layer and configured to discharge
cooling air to the dead layer.
[0007] According to the present invention, since the diffuser tubes through which the cooling
air is supplied are provided separately from the bottom plate, it becomes unnecessary
to configure a labyrinth, through which the cooling air is supplied, on the bottom
plate. With this, the granular substances can be prevented from falling from the bottom
plate.
[0008] In the present invention, since the diffuser tubes can be embedded in the dead layer,
the cooling air discharged from the diffuser tubes can be supplied through the dead
layer to the granular conveyed substances. With this, an appropriate passage pressure
loss can be given to the cooling air, and appropriate heat exchange can be performed.
Thus, the granular conveyed substances can be cooled uniformly.
[0009] Further, in the present invention, since the diffuser tubes can be embedded in the
dead layer constituted by the low-temperature granular embedded substances provided
on the bottom plate, the diffuser tubes do not directly contact the high-temperature
granular conveyed substances. Therefore, the diffuser tubes can be prevented from
being damaged by heat and being worn away by the conveyance of the granular conveyed
substances.
[0010] In the above invention, it is preferable that: each of the diffuser tubes be arranged
parallel to a conveying direction in which the granular conveyed substances are conveyed
and include a plurality of diffuser openings through which the cooling air is discharged;
and the plurality of diffuser openings be arranged on each of the diffuser tubes so
as to be spaced apart from one another in the conveying direction.
[0011] According to the above configuration, the diffuser tubes extend in the conveying
direction, and the diffuser openings are arranged so as to be spaced apart from one
another in the conveying direction. Therefore, the granular conveyed substances can
be uniformly cooled in the cooler apparatus configured to convey the granular conveyed
substances while repeating the movement and stop of the granular conveyed substances.
[0012] According to the present invention, the cooling air is supplied through the plurality
of diffuser openings. Therefore, by appropriately setting the opening areas of the
diffuser openings, the number of diffuser openings, and the positions of the diffuser
openings, the heat exchange between the cooling air and the high-temperature cement
clinkers can be performed appropriately.
[0013] In the above invention, it is preferable that the diffuser openings be open downward.
[0014] According to the above configuration, the granular embedded substances can be prevented
from getting into the diffuser tubes through the diffuser openings.
[0015] In the above invention, it is preferable that: the plurality of diffuser tubes and
headers which couple the plurality of diffuser tubes to one another and through which
the cooling air is supplied to the diffuser tubes be provided at such positions as
to be embedded in the dead layer; and the headers be arranged so as to extend in a
direction orthogonal to the conveying direction.
[0016] According to the above configuration, the cooling air can be supplied to the plurality
of diffuser tubes at once by the headers.
[0017] In the above invention, it is preferable that the supporting member include walls
standing on an outer peripheral edge portion of the bottom plate and be configured
in a box shape.
[0018] According to the above configuration, the granular embedded substances can be prevented
from falling down from not only the bottom side but also front, rear, left, and right
sides.
[0019] A cooler apparatus of the present invention includes a plurality of cooling unit
trains each configured such that the above cooling units are arranged in a row in
the conveying direction, wherein the plurality of cooling unit trains are arranged
in parallel with one another in a direction orthogonal to the conveying direction.
[0020] According to the above configuration, the cooler apparatus having the above functions
can be realized.
[0021] The above object, other objects, features, and advantages of the present invention
will be made clear by the following detailed explanation of preferred embodiments
with reference to the attached drawings.
Advantageous Effects of Invention
[0022] The present invention can uniformly cool granular substances to be conveyed and prevent
not only large granular substances but also finely-granular substances from falling
down.
Brief Description of Drawings
[0023]
[Fig. 1] Fig. 1 is a schematic diagram showing the configuration of a cement plant
including a cooler apparatus according to the present invention.
[Fig. 2] Fig. 2 is a perspective view schematically showing the configuration of the
cooler apparatus of Fig. 1.
[Fig. 3] Fig. 3 is a front view showing the configuration of a cooling unit included
in the cooler apparatus of Fig. 2.
[Fig. 4] Fig. 4 is a cross-sectional view taken along line A-A of Fig. 3 and showing
the configuration of the cooling unit.
[Fig. 5] Fig. 5 is an enlarged cross-sectional view of the vicinity of a diffuser
tube shown in Fig. 4.
Description of Embodiments
[0024] Hereinafter, a cooling unit 1 according to an embodiment of the present invention
and a cooler apparatus 2 including the cooling unit 1 will be explained in reference
to the above-described drawings. The concept of directions, such as upper, lower,
left, right, front, and rear directions, in the embodiment is used for convenience
of explanation and does not indicate that the arrangements, directions, and the like
of components of the cooling unit 1 and the cooler apparatus 2 are limited to the
directions. Each of the cooling unit 1 and the cooler apparatus 2 explained below
is just one embodiment of the present invention, and the present invention is not
limited to the embodiment. Additions, deletions, and modifications may be made within
the scope of the present invention.
Cement Plant
[0025] Cement is produced through a raw material grinding step of grinding cement raw meal
containing limestone, clay, silica stone, iron, and the like, a pyroprocessing step
of firing the ground cement raw meal, and a finishing step that is the last step.
These three steps are performed at a cement plant. In the pyroprocessing step that
is one of these three steps, the ground cement raw meal is fired and cooled, and thus,
granular cement clinkers are produced. Fig. 1 shows a pyroprocessing facility 3 of
the cement plant, and the pyroprocessing facility 3 being a portion where the pyroprocessing
step in cement manufacturing is performed. The pyroprocessing facility 3 performs
preheating, calcinating, and sintering of the cement raw meal ground in the raw material
grinding step and cools the granular cement clinkers that are high in temperature
by the sintering.
[0026] The portion where the pyroprocessing step is performed will be explained in further
detail. The pyroprocessing facility 3 includes a preheater 4, and the preheater 4
is constituted by a plurality of cyclones 5. The cyclones 5 are arranged in an upper-lower
direction so as to be provided in a stepped manner. Each cyclone 5 causes exhaust
gas therein to flow upward to the cyclone 5 at an upper stage (see broken line arrows
in Fig. 1), separates the put cement raw meal from one another by rotational flow,
and puts the cement raw meal into the cyclone 5 at a lower stage (see solid line arrows
in Fig. 1). The cyclone 5 located immediately above the cyclone 5 at a lowermost stage
puts the cement raw meal into a precalciner 6. The precalciner 6 includes a burner.
By heat of the burner and heat of below-described exhaust gas, the precalciner 6 performs
a reaction (that is, a calcination reaction) by which carbon dioxide is separated
from the put cement raw meal. The cement raw meal subjected to the calcination reaction
in the precalciner 6 is introduced to the cyclone 5 at the lowermost stage as described
below, and the cement raw meal in this cyclone 5 is then supplied to a rotary kiln
7.
[0027] The rotary kiln 7 is formed in a horizontally long cylindrical shape having several
tens of meters or longer. The rotary kiln 7 is arranged so as to be slightly inclined
downward from an inlet located at the cyclone 5 side toward an outlet located at a
tip end side. Therefore, by rotating the rotary kiln 7 about an axis, the cement raw
meal at the inlet side is conveyed toward the outlet side. A combustion device 8 is
provided at the outlet of the rotary kiln 7. The combustion device 8 generates high-temperature
flame to sinter the cement raw meal.
[0028] The combustion device 8 ejects a high-temperature combustion gas toward the inlet
side, and the combustion gas ejected from the combustion device 8 flows in the rotary
kiln 7 toward the inlet while sintering the cement raw meal. The combustion gas that
is high-temperature exhaust gas flows as jet flow upward through a lower end of the
precalciner 6 in the precalciner 6 (see a broken line arrow in Fig. 1) to cause the
cement raw meal, put in the precalciner 6, to flow upward. The cement raw meal is
heated by the exhaust gas and the burner up to about 900°C, that is, is subjected
to the calcinating. The flown cement raw meal flows into the cyclone 5 at the lowermost
stage together with the exhaust gas, and the flown exhaust gas and cement raw meal
are separated from each other in the cyclone 5 at the lowermost stage. The separated
cement raw meal is supplied to the rotary kiln 7, and the separated exhaust gas flows
upward to the cyclone 5 located immediately above the cyclone 5 at the lowermost stage.
The flown exhaust gas performs heat exchange with the cement raw meal in each cyclone
5 to heat the cement raw meal. Then, the exhaust gas is separated from the cement
raw meal again. The separated exhaust gas flows upward to the cyclone 5 located above
to repeat the heat exchange. Then, the exhaust gas is discharged to the atmosphere
through the cyclone 5 at an uppermost stage.
[0029] In the pyroprocessing facility 3 configured as above, the cement raw meal is put
through the vicinity of the cyclone 5 at the uppermost stage, is adequately subjected
to preheating while performing the heat exchange with the exhaust gas, moves down
to the cyclone 5 located immediately above the cyclone 5 at the lowermost stage, and
is then put into the precalciner 6. In the precalciner 6, the cement raw meal is subjected
to the calcinating by the burner and the high-temperature gas. Then, the cement raw
meal is introduced to the cyclone 5 at the lowermost stage. The cement raw meal is
separated from the exhaust gas in the cyclone 5 at the lowermost stage to be supplied
to the rotary kiln 7. The supplied cement raw meal is conveyed to the outlet side
while being subjected to the sintering in the rotary kiln 7. Through the preheating,
the calcinating, and the sintering, the cement clinkers are shaped. The cooler apparatus
2 is provided at the outlet of the rotary kiln 7, and the shaped cement clinkers are
discharged from the outlet of the rotary kiln 7 to the cooler apparatus 2.
Cooler Apparatus
[0030] The cooler apparatus 2 cools the cement clinkers (high-temperature granular conveyed
substances), discharged from the rotary kiln 7, while conveying the cement clinkers
in a predetermined conveying direction. As shown in Fig. 2, the cooler apparatus 2
includes a fixed inclined grate 11 located immediately under the outlet of the rotary
kiln 7. The fixed inclined grate 11 is inclined downward from the outlet side of the
rotary kiln 7 toward the conveying direction. The granular cement clinkers discharged
from the outlet of the rotary kiln 7 roll down on the fixed inclined grate 11 in the
conveying direction. A plurality of cooling unit trains 13 are provided at a conveying-direction
tip end portion of the fixed inclined grate 11. The cement clinkers are deposited
on the plurality of cooling unit trains 13 to form a clinker layer 14.
[0031] The cooling unit trains 13 are structures each extending in the conveying direction.
The cooling unit trains 13 are arranged in parallel with one another in a crosswise
direction (hereinafter referred to as an "orthogonal direction") orthogonal to the
conveying direction so as to be adjacent to one another and not to form a gap between
the adjacent cooling unit trains 13. Portions each between the cooling unit trains
13 are sealed to prevent the cement clinkers from falling down. The clinker layer
14 (see a chain double-dashed line in Fig. 2) is placed on the plurality of cooling
unit trains 13, arranged in parallel with one another and sealed without the formation
of the gaps, so as to entirely cover the plurality of cooling unit trains 13.
[0032] The plurality of cooling unit trains 13 convey the clinker layer 14 in the conveying
direction while cooling the clinker layer 14. The granular cement clinkers are conveyed
while the movement and stop of the clinker layer 14 are repeated on the cooling unit
trains 13. Examples of a specific conveying method include: a method of causing all
the cooling unit trains 13 to move forward and then causing the cooling unit trains
13 to move backward in such a manner that the cooling unit trains 13 not adjacent
to one another are moved backward, and this is performed plural times; and a method
of providing a crossbar extending in the orthogonal direction at an upper position
of the cooling unit trains 13 and causing the crossbar to move in the conveying direction
to transfer the clinker layer 14 in the conveying direction. The configuration and
method of transferring the clinker layer 14 in the conveying direction are not limited
to the above, and any configuration and method may be adopted as long as the clinker
layer 14 can be transferred in the conveying direction. Each of the cooling unit trains
13 configured as above includes a plurality of cooling units 1 and is configured such
that the cooling units 1 are arranged in a row in the conveying direction.
[0033] As shown in Figs. 3 and 4, the cooling unit 1 includes a box-shaped casing 21 having
a substantially rectangular parallelepiped shape. The casing 21 includes a flat bottom
plate 21 a at a lower side, and an upper side thereof is open. The casing 21 includes
four walls 21b to 21e standing on the bottom plate 21 a. Headers 22 each extending
in the orthogonal direction are provided at the bottom plate 21 a of the casing 21
configured as above.
[0034] The header 22 has a U-shaped cross section having an opening at a lower side. Opening
grooves 21f each extending in the orthogonal direction are respectively formed at
positions of the bottom plate 21a, the positions respectively corresponding to the
openings of the headers 22. Each of the headers 22 extends from the side wall 21 d
to the side wall 21 e, and left and right end portions of the header 22 are respectively
closed by the side walls 21 d and 21 e. With this, a supply passage 22a communicating
with a lower space 23 located under the bottom plate 21 a is formed in each header
22. A cooling air supply unit 24 (see Fig. 2) configured to supply cooling air communicates
with the lower space 23 located under the bottom plate 21 a. The cooling air is supplied
to the supply passages 22a through the lower space located under the bottom plate
21 a. A plurality of (in the present embodiment, two) headers 22 configured as above
are arranged in the casing 21 so as to be spaced apart from one another in the conveying
direction. A plurality of diffuser tubes 25 are provided at the headers 22.
[0035] The diffuser tubes 25 are cylindrical members each extending in the conveying direction.
The diffuser tubes 25 are located so as to be spaced apart from one another in the
orthogonal direction. The diffuser tubes 25 are provided between the adjacent two
headers 22, between the header 22 and the front wall 21b, and between the header 22
and the rear wall 21c. Each of the diffuser tubes 25 includes therein a cooling passage
25a, and the cooling passage 25a communicates with the supply passage 22a of the header
22. An end portion of the diffuser tube 25 provided at the front wall 21b and an end
portion of the diffuser tube 25 provided at the rear wall 21c are respectively closed
by the front wall 21b and the rear wall 21c. The cooling air is supplied from the
headers 22 to the diffuser tubes 25 to flow through the cooling passages 25a. Each
of the diffuser tubes 25 includes a plurality of diffuser openings 26.
[0036] As shown in Fig. 5, in a plane orthogonal to an axis of the diffuser tube 25 and
in a lower half plane of the diffuser tube 25, the diffuser openings 26 are arranged
at both sides in the orthogonal direction so as to be separated from each other and
are open in a radial direction and an obliquely downward direction. The diffuser openings
26 are formed on the diffuser tube 25 so as to be located at substantially regular
intervals in the conveying direction. The diffuser tube 25 is located upwardly away
from the bottom plate 21a by a height h such that the diffuser openings 26 thereof
are not covered with the bottom plate 21 a. In addition, the diffuser tube 25 is provided
parallel to the bottom plate 21 a. With this, the cooling air flowing in the diffuser
tubes 25 is discharged through the diffuser openings 26 to the outside.
[0037] Cement clinkers having a temperature (for example, a normal temperature from 20 to
60°C) lower than the temperature of the typical cement clinkers discharged from the
kiln 7 are put in the casing 21 in which the diffuser tubes 25 are provided. The casing
21 is filled with the cement clinkers. With this, the cement clinkers are deposited
on the bottom plate 21 a to form a dead layer 27 (see a chain double-dashed line in
Figs. 3 to 5). The granular cement clinkers to be conveyed (clinker layer 14; see
a chain double-dashed line in Figs. 3 and 4) are placed on the dead layer 27, and
the bottom plate 21 a supports the granular cement clinkers (clinker layer 14) via
the dead layer 27.
[0038] Since the casing 21 is filled with the cement clinkers, the diffuser tubes 25 are
buried in the dead layer 27. That is, the diffuser tubes 25 are embedded in the dead
layer 27. Since the diffuser tubes 25 are buried in the dead layer 27 as above, the
cooling air discharged from the diffuser tubes 25 can flow through gaps among the
cement clinkers of the dead layer 27 to be supplied to the clinker layer 14 located
on the dead layer 27. With this, the dead layer 27 can give an appropriate passage
pressure loss to the cooling air.
[0039] The passage pressure loss of the dead layer 27 becomes a value corresponding to the
height of the dead layer 27 and the positions and sizes of the diffuser openings 26,
and the height of the dead layer 27 formed by filling the casing 21 with the cement
clinkers is determined in accordance with the side walls 21 d and 21 c of the casing
21. Therefore, the passage pressure loss of the dead layer 27 is set as a value corresponding
to the shape of the casing 21 and the positions of the diffuser openings 26. The passage
pressure loss of the entire cooling unit 1 can be set to a desired value by appropriately
setting the height h of the diffuser tube 25, the diameter of each diffuser opening
26, and the number of diffuser openings 26.
[0040] By setting the passage pressure loss to the desired value as above, it is possible
to prevent uneven flow of the cooling air in the clinker layer 14, the uneven flow
being caused by the unevenness of the height of the clinker layer 14 and the bias
of the distribution of the particle diameters of the cement clinkers. To be specific,
the cooling air of a substantially uniform flow rate can be supplied to the clinker
layer 14 to uniformly cool the clinker layer 14. More specifically, by setting the
passage pressure loss of the entire cooling unit 1 to an appropriate value, it is
possible to reduce a ratio of the pressure loss caused by the unevenness of the height
of the clinker layer 14 and the bias of the distribution of the particle diameter
of the cement clinkers to the passage pressure loss of the cooling unit 1 and the
clinker layer 14. With this, the cooling air flows in a substantially upward direction
in the clinker layer 14, and the uneven flow of the cooling air can be prevented.
Therefore, the clinker layer 14 can be cooled uniformly.
[0041] Since the diffuser tubes 25 are embedded in the dead layer 27, the diffuser tubes
25 do not directly contact the clinker layer 14 that is high in temperature and moving.
Therefore, the diffuser tubes 25 can be prevented from being damaged by heat and being
worn away by the movement of the clinker layer 14.
[0042] Further, by using the diffuser tubes 25, it becomes unnecessary to form grooves or
holes, through which the cooling air is supplied, on the bottom plate 21a as in conventional
arts. Therefore, the cement clinkers and the granular cement clinkers are prevented
from falling down from the bottom plate 21a. Since the walls 21b to 21e are provided
in the conveying direction and the orthogonal direction, the cement clinkers can be
prevented from falling down from the casing 21 in the conveying direction and the
orthogonal direction (that is, in the front, rear, left, and right directions). Further,
since the diffuser openings 26 of the diffuser tubes 25 are open in the obliquely
downward direction, the cement clinkers can be prevented from getting into the diffuser
tubes 25 through the diffuser openings 26. To be specific, each diffuser opening 26
is formed at such an angle θ that the cement clinkers and the granular cement clinkers
do not get into the diffuser tubes 25 through the diffuser openings 26. With this,
the diffuser openings 26 and the diffuser tubes 25 can be prevented from being clogged
by the cement clinkers, and the cooling air can be supplied through the dead layer
27 to the clinker layer 14 at a desired flow rate.
[0043] According to the cooler apparatus 2 configured as above, the granular cement clinkers
discharged from the rotary kiln 7 are received by the fixed inclined grate 11 to be
caused to roll toward the cooling unit trains 13. Then, the cement clinkers are deposited
on the cooling unit trains 13 to form the clinker layer 14 on the cooling unit trains
13, and the clinker layer 14 is conveyed in the conveying direction by the above-described
method. During the conveyance, the cooling air supply unit 24 (fan) is operating,
and the cooling air is supplied from the cooling air supply unit 24 through the lower
space 23 to the supply passages 22a of the headers 22. The cooling air in the headers
22 are supplied to the cooling passages 25a of the plurality of diffuser tubes 25
at once to be discharged through the diffuser openings 26 to the outside. The cooling
air discharged through the diffuser openings 26 flows upward through the gaps among
the cement clinkers of the dead layer 27 to reach the clinker layer 14. The cooling
air performs heat exchange with the granular cement clinkers of the clinker layer
14 to flow through the gaps among the granular cement clinkers of the clinker layer
14 while cooling the granular cement clinkers of the clinker layer 14. Then, the cooling
air is discharged upward from an upper portion of the clinker layer 14. The air discharged
upward is high in temperature by the heat exchange with the granular cement clinkers.
Apart of the high-temperature air is discharged from the cooler apparatus 2 to be
directly introduced to the kiln 7 or to be introduced through a discharge pipe 31
to the precalciner 6.
[0044] According to the cooler apparatus 2, the granular cement clinkers of the clinker
layer 14 are conveyed while being cooled by the cooling unit 1 as above, and the granular
cement clinkers are continuously cooled down to a temperature higher than an atmospheric
temperature by several tens of degrees.
Other Embodiments
[0045] In the above embodiment, the cement clinkers are used as the granular substances
forming the dead layer 27. However, heat-resistant granular substances, such as metal
granular substances or ceramic granular substances, other than the cement clinkers
may be used. The sizes of the particle diameters of the granular substances to be
conveyed and the sizes of the particle diameters of the granular substances forming
the dead layer 27 are not limited. The outer shapes and arrangement positions of the
diffuser tubes 25 are not limited to the above. The diffuser tubes 25 may be orthogonal
to the conveying direction and may be formed in an accordion shape. In the above embodiment,
the bottom plate 21a is a flat plate. However, the bottom plate 21a may be a V-shaped
plate projecting downward or upward or an inclined plate inclined in the orthogonal
direction or the conveying direction.
[0046] From the foregoing explanation, many modifications and other embodiments of the present
invention are obvious to one skilled in the art. Therefore, the foregoing explanation
should be interpreted only as an example and is provided for the purpose of teaching
the best mode for carrying out the present invention to one skilled in the art. The
structures and/or functional details may be substantially modified within the spirit
of the present invention.
Reference Signs List
[0047]
- 1
- cooling unit
- 2
- cooler apparatus
- 13
- cooling unit train
- 14
- clinker layer
- 21
- casing
- 21a
- bottom plate
- 22
- header
- 25
- diffuser tube
- 26
- diffuser opening
- 27
- dead layer