Updations in Gas Cooling Technology
Continuous Emission Monitoring Systems
IN THE TOP CYCLONES 
CONDITIONING SYSTEMS 
Clinker Cooler Bed
Gas Conditioning in
 
2. ITALCHEMENTI, VISHNU CEMENT UNIT
3. ULTRATECH CEMENT, AWARPUR CEMENT WORKS - 4 SYSTEMS
4. ULTRATECH CEMENT, ADITYA CEMENT WORKS
5. ULTRATECH CEMENT, NARMADA CEMENT WORKS
6. MADRAS CEMENT, ALATHIYUR CEMENT WORKS – 2 SYSTEMS
7. MADRAS CEMENT, ARIYALUR CEMENT WORKS – 2 SYSTEMS
8. SANGHI CEMENT, SANGHIPURAM
11. J.K.LAKSHMI CEMENT , UNIT – 1
12. SANGHI CEMENT, SANGHIPURAM – 2 SYSTEMS (UNDER
MANUFACTURE)
 
14/03/2011
4
The cooled gas leaving the Cyclone occupies less volume, enabling substantial
power savings for the PH fan.
In the Cyclone Water Spray
System – cooling water is
down the hot gas.
While the high pressure
it also agglomerates & forces
the collection ratio &
 
14/03/2011
5
THE MAJOR COMPONENTS OF GAS COOLING SY STEM IN THE TOP CYCLONES
PUMP STATION : pumps are VFD controlled.  – ENER GY SAVING
Use of vertical pumps where ever possible  – again Power Savings
THE MAJOR COMPONENTS GAS COOLING IN THE TOP CYCLONES
LANCES & SPRAY NOZZLES : HIGH PERFORMACE HIGH PRESSURE LANCES, NO
 
CHEMTROLS USES THEIR OWN SOFTWARE FOR
‘’HEAT TRANSFER CALCULATIONS IN GAS COOLING’’ 
 
CHEMTROLS USES THEIR OWN SOFTWARE FOR
‘’HEAT TRANSFER CALCULATIONS IN GAS COOLING’’ 
 
 
The overall control 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.
CASE STUDY 1
CASE STUDY 1 : J. K. LAKSMI CEMENT  WITHOUT WATER SPRAY
CASE STUDY 1 : J. K. LAKSMI CEMENT 
WITH WATER SPRAY
increase
temperature drop
ID Fan (rpm) 786,85 686,43 Less 12,7%
ID Fan (KW) 918,24 711,87 Less by 206 KW
Hybrid Bag DP
CASE STUDY 2 : KUWAIT CEMENT 
WITHOUT GAS
COOLING SYSTEM
WITH GAS COOLING
WITHOUT GAS
COOLING SYSTEM
WITH GAS COOLING
PARAMETERS
BEFORE
increase
327 °C / 345 °C 274 °C/271 °C 53 / 74 °C
O Content 3.8% / 3.6% 3.8% / 3.9%
Dilution Damper pos. 99% open 20% open
ID Fan (rpm) 982 961
ID Fan (KW) 1321 1326
Bag filter discharge
GENERAL PROCESS
SYSTEM
INSTALLATION
2 Preheater Fan
3 Bag House Fan
8 5 3 hrs savings
5 Reverse Air Fan
 
ILC STRING
C2 STRING
SLC STRING
CASE STUDY – 4 SANGHI CEMENT
Case-1: Plant operation at 9500 TPD without water spray - RM Stopped
Heat Balance Calculation 1 2 3 4 Raw Mill Bag house
Design capacity – 
   t  u   r  e
   d   r  o   p
  c   o   n   s
   d
Total water requred
streams 123 & 4 = 1234 249
Resultant volume of gas Nm3/hr - 1234 1,010,967
Resultant volume of gas Am3/hr - 1234 1,934,130
Gas drawn for one Coal Mill 180,000
Volume of gas at Bag.House inlet with 1 Coal mill running 1,754,130
Volume of gas at Bag.House inlet with 2 Coal mills running 1,574,130
Moisture addition % 0.00
Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas
handling capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,574,000 m3/hr @
2500C
CASE STUDY – 4 SANGHI CEMENT
Case-2: Plant operation at 9500 TPD with water spray in ILC top stage cyclone (present
operating condition)- RM Stopped
Heat Balance Calculation 1 2 3 4 Raw Mill Bag house
Design capacity -
   t  u   r  e
   d   r  o   p
  c   o   n   s
   d
Operating flow rate
Calculated water flow rate for cooling in m3/hr 8 0 0 0 Total water requred
m3/hr 8
Resultant temperature due to mixing of gas streams 123 & 4 =
1234 248
Resultant volume of gas Nm3/hr - 1234 933,731
Resultant volume of gas Am3/hr - 1234 1,782,818
Gas drawn for one Coal Mill 180,000
Volume of gas at Bag.House inlet with 1 Coal mill running 1,602,818
Volume of gas at Bag.House inlet with 2 Coal mills running 1,422,818
Moisture addition % 1.07
Note: The junction duct gets pressurised even after operation of both coal mill as baghouse gas handling
capacity is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,422,818 m3/hr @ 2500C
CASE STUDY – 4 SANGHI CEMENT
Case-3: Plant operation at 9500 TPD with water spray in ILC, SLC & C2 string top cyclone - RM
Stopped
Heat Balance Calculation 1 2 3 4 Raw Mill Bag
house Design
provided by SIL
   T   e   m   p   e   r  a    t  u   r  e    d   r  o   p
  c   o   n   s    i   d   e   r  e    d
Dilution
air
Operating
conditions
Calculated water flow rate for cooling in m3/hr 12 13 7 0 Total water
requred m3/hr 32
6 6 6 0 Resultant temperature due to mixing of gas streams
123 & 4 = 1234 251
Resultant volume of gas Nm3/hr - 1234 683,870
Resultant volume of gas Am3/hr - 1234 1,312,258
Gas drawn for one Coal Mill 180,000
Volume of gas at Bag.House inlet with 1 Coal mill running 1,132,258
Volume of gas at Bag.House inlet with 2 Coal mills running 952,258
Moisture addition % 5.74
Note: The junction duct will not get pressurised after installation of the water spray system in SLC
& C2 string and operation of both coal mills.
 
CASE STUDY – 4 SANGHI CEMENT
Case-5: Plant operation at 10,500 TPD with water spray in ILC, SLC & C-2 (Maximum
Operating capacity)- RM Stopped
Heat Balance Calculation 1 2 3 4 Raw Mill Bag house fan
Design capacity - 1,280,000 m3/hr @
   t  u   r  e
   d   r  o   p
  c   o   n   s
   d
conditions
Calculated water flow rate for cooling in m3/hr 7 7 5 0 Total water requred
m3/hr 19
Resultant temperature due to mixing of gas streams 123 & 4 =
1234 240
Resultant volume of gas Nm3/hr - 1234 802,138
Resultant volume of gas Am3/hr - 1234 1,506,384
Gas drawn for one Coal Mill 180,000
Volume of gas at Bag.House inlet with 1 Coal mill running 1,326,384
Volume of gas at Bag.House inlet with 2 Coal mills running 1,146,384
Moisture addition % 2.98
Note: The junction duct will not get pressurised by operating both coal mills as baghouse gas handling capacity
is 1,288,000 m3/hr @ 2600C and available gas at inlet is 1,146,385 m 3/hr @ 2400C
SUMMARY – GAS COOLING IN TOP CYCLONE
ENERGY SAVING IN ID FAN= YES
PRODUCTION INCREASE = YES
PROCESS = YES
INCREASED CYCLONE RETENTION EFFICIENCY = YES
– THE ONLY MANUFACTURER IN THE
WORLD-
water ~38 bars
2. MAIHAR CEMENT, SARALANAGAR  – 2 SYSTEMS
3. ORIENT CEMENT , DEVAPUR WORKS – 3 SYSTEMS
4. ULTRATECH CEMENT, HIRMI CEMENT WORKS – 2 SYSTEMS
5. KANORIA CEMENT, BAGALKOT CEMENT WORKS
DENZILI CEMENT, ISTANBUL – 2 SYSTEMS 
SET BALIKESIR, ISTANBUL 
GAS COOLING SYSTEM
This is a combination of Spillback & High Pressure lances in the tower replacing the conventional Single nozzle or cluster lances.
These can be fitted in the same protection pipe of the Chemtrols High performance single nozzle lance.
50% to 70% lances will be high pressure fixed volume spray  – No return- flow control – The lances are with 5 nozzles.
Balance lances are spillback with return-flow control -These lances are cluster with 3 nozzles.
This combination allows better atomization and performance of the system.
The flow control of water will be from 50% to 100% of the total water injection rate. During the stable plant operation this variation is sufficient for control.
If higher rangability is required, the high pressure lances can be arranged in 2 or 3 stages with ON/OFF valves for each stage.
HIGH PERFORMANCE LANCES
& groove connection
1. The most important component in the gas conditioning system is the New generation high
performance lances, which has an inbuilt filter and an NRV as integral part of the lance.
2. These are user friendly, light and robust for the application.
 
HIGH PRESSURE
LANCE SPRAY
OTHER ACTIVITIES OF CHEMTROLS
Dryfog for Raw material Preparation section
DeNOx Systems for Cement plants by
CHEMTROLS-ERC a Joint venture with ERC
Germany.
Industries Ltd.
 
CEMS Typical layout
Alternate Fuels, the
following Gases are
measured.
• SO2
• NOx
• NH3
• HCl
• Hydrocarbons