Conversion of a 3000 TPD planetary cooler kiln to grate cooler in less than 50 days

In October 1995 a total of seven serious cracks were discovered on the tyre uphill of the planetary coolers (Tyre 2) and two smaller cracks on the tyre downhill of the coolers (Tyre 1) of the Platin cement plant of Irish Cement Limited (ICL). New tyres were ordered immediately, and an evaluation of the possible causes was undertaken. No mathematical reason for the cracks could be discovered, the story throughout the industry being that such cracks could be expected at the age and duty history of the kiln. This paper describes the option of replacing the entire planetary cooler arrangement with a grate cooler which was examined as a potential alternative to the repair of the above.