polytrack® eco – The Next Generation Clinker Cooler

Energy-efficient clinker cooling for cement plants

The polytrack® eco by thyssenkrupp Polysius is the next generation clinker cooler technology, designed to maximize energy efficiency and process reliability. With its innovative moving floor system, optimized aeration grate, and modular hydraulic design, the polytrack® eco offers an advanced clinker cooling system that reduces power consumption and maintenance while enhancing overall plant productivity.The polytrack^® is the reliable clinker cooler of thyssenkrupp. The focal point of our quest for continuous innovation and optimization of the polytrack^® reflects our commitment to meet the demands of the cement industry. With the polytrack^®, thyssenkrupp offers a robust machine that keeps delivering high performance under challenging process conditions not only today, but for years to come.

Key Features at a glance

The polytrack® eco sets new benchmarks in energy efficiency:

• Cooling efficiency: Achieves 76% cooling efficiency, ensuring maximum heat recovery.

• Conveying efficiency: Exceeds 86% conveying efficiency for seamless material transport.

• Low clinker outlet temperature: Delivers a clinker outlet temperature of just 65°C above ambient, reducing energy losses.

• Reduced power consumption: Operates with a power consumption of less than 4 kWh per ton of clinker.

• Oxyfuel-ready design: Prepared for future integration with oxyfuel technology, supporting sustainability initiatives.

Your Benefits

• High availability and robustness: Engineered for continuous operation in demanding conditions, ensuring consistent performance for clinker cooling solutions.

• Modular and flexible design: Allows for quick installation, making it a versatile modular clinker cooler.

• Superior thermal efficiency: Optimized for high-efficiency clinker cooling with lower energy consumption, reducing operational costs.

• Low wear and maintenance-friendly: Designed to minimize wear, making it a low-maintenance clinker cooler, reducing downtime and maintenance efforts.

• Cost-effective investment: Provides an attractive balance between initial investment and long-term operational savings in cement plant cooling systems.

Operating principle

Stationary, low-wear aeration grate

The polytrack® eco utilizes a static aeration floor combined with a moving clinker conveying system. This setup ensures even air distribution across the clinker bed, improving advanced clinker cooling performance. The high-performance aeration design protects the aeration plates with a cold clinker layer, significantly reducing wear and extending component life. As a result, spillage-free clinker cooling is achieved, eliminating the need for an undergrate spillage conveyor.

Advanced hydraulic system

Equipped with a European-manufactured, open-loop hydraulic system, the polytrack® eco cooler ensures precise control of track movement. The system’s modular design reduces the number of hydraulic cylinders required, simplifying maintenance and enhancing reliability. Standardized components and factory acceptance testing (FAT) of each unit prior to shipment guarantee quality and facilitate shorter delivery times. Additionally, the clinker cooler automatically adapts to varying operating conditions. Depending on the set clinker bed height parameters such as hydraulic pressure and grates speed are adjusted automatically to maintain the set bed height. 

Efficient roller crusher

The integrated roll crusher for clinker is designed for low wear and high performance. Typically featuring three to five rolls, it efficiently reduces clinker size with minimal power consumption. The crusher’s electromechanical drive supports capacities of up to 9,000 tons per day, operating at low speeds to minimize wear and extend component life.