Cooler Side Wall Erosion

Grate Cooler · Side Walls

Problem Details

Background

The grate cooler side walls line both sides of the clinker cooling channel, long-term bearing hot-clinker radiation, abrasion and secondary/tertiary air scouring. Side-wall brick erosion and thinning are common cooler lining issues, directly affecting cooling efficiency and equipment life.

Failure Mechanism

Clinker radiation and abrasion: hot clinker moving on the grate radiates and abrades side walls. Gas scouring: secondary/tertiary air carrying clinker dust scours the walls. Thermal shock: kiln swings and shutdowns cause rapid temperature changes, thermally shocking the bricks. Mechanical collision: maintenance and cleaning operations collide with the bricks.

Consequences

After thinning, the cooler shell overheats and deforms and cooling efficiency drops; fallen bricks may plug grate openings or damage equipment, forcing kiln shutdown for repair.

Solution

Material Selection and Parameters

Select cooler side walls for "wear resistance + thermal-shock resistance":

Material system: high-alumina brick (Al₂O₃≥65%) or SiC brick (SiC≥85%). High-alumina offers value; SiC resists wear and conducts heat for hot-gas scouring zones;
Structural design: zone the side-wall lining by cooling-air sections, thickening the hot zones;
Joint materials: lay with high-alumina mortar and tight joints.

Installation Essentials

Masonry control: lay with staggered joints, full mortar and joints ≤2mm. Locking: lock circumferentially against loosening. Bake-out: follow the curve to avoid residual moisture in mortar.

Maintenance

Monitor cooler shell temperature and cooling air pressure; investigate on anomalies. At maintenance, measure side-wall residual thickness and replace thinned zones; record data to optimize grade and thickness.

Recommended Products

Silicon Carbide Brick

Silicon carbide brick (SiC≥85%, refractoriness ≥1900℃, CCS≥120MPa) offers high thermal conductivity, extreme wear resistance, thermal-shock resistance and molten-salt resistance—preferred for waste incineration and hot abrasion duties.

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High-Alumina Brick LZ-65

High-alumina brick LZ-65 (Al₂O₃≥65%, refractoriness ≥1790℃) has a higher corundum/mullite phase ratio for stronger slag resistance, higher temperature rating and better hot load-bearing capacity.