Polysius
polytrack® eco – The Next Generation Clinker Cooler
Maximum energy efficiency, minimal wear: polytrack® eco by thyssenkrupp Polysius sets new benchmarks in clinker cooling. An innovative moving-floor system, optimized aeration grate and modular hydraulic design come together to significantly reduce power consumption and maintenance – while boosting overall plant productivity.
polytrack® eco by thyssenkrupp Polysius is the next generation of clinker cooler technology, engineered to maximize energy efficiency and process reliability. Combining an innovative moving-floor system, an optimized aeration grate and a modular hydraulic design, the polytrack® eco reduces power consumption and maintenance while enhancing overall plant productivity.
The polytrack® is the proven clinker cooler from thyssenkrupp. Our continuous drive to innovate and optimize reflects our commitment to the demands of the cement industry – a robust machine that keeps delivering high performance under challenging process conditions, today and for years to come.
Reliable cooling for modern cement plants
In cement production, clinker leaves the rotary kiln at 1,300–1,400 °C and must be cooled reliably to below 100 °C before it can be processed into the final product. This is the task of the clinker cooler. With the polytrack® eco, thyssenkrupp introduces a newly engineered cooling system that redefines this critical process – built from the ground up for maximum efficiency.
Key features at a glance
The polytrack® eco sets new benchmarks in energy efficiency:
- Coolin efficiencyachieves 76 % cooling efficiency for maximum heat recovery.76
- Conveying efficiencyexceeds 86 % for seamless material transport.86
- Low clinker outlet temperaturejust 65 °C above ambient, reducing energy losses.65
- Reduced power consumptionoperates at less than 4.5 kWh per tonne of clinker.4.5
Your benefits
High availability and robustness: engineered for continuous operation in demanding conditions, ensuring consistent cooling performance.
Modular and flexible design: pre-assembled components allow quick installation and short downtimes.
Superior thermal efficiency: high-efficiency clinker cooling at lower energy consumption reduces operational costs.
Low wear and maintenance-friendly: a design that minimizes wear reduces downtime and maintenance effort.
Cost-effective investment: an attractive balance between initial investment and long-term operational savings.
Sustainability and future-readiness
The polytrack® eco is built for the decarbonization of cement production. Optimized aeration elements and a reduced pressure drop lower power consumption, while the oxyfuel-ready design prepares the cooler for future carbon-capture concepts. In such operation, surplus cooler heat is available at a high temperature level for waste heat recovery (WHR) and drying processes – combining immediate efficiency gains with long-term future-proofing.
Modularity, retrofit and service
Thanks to modular components, the polytrack® eco adapts to any plant size and integrates into existing clinker production lines. Upgrades are also possible for existing coolers – including third-party equipment: our experts either modernize the complete cooler or replace only the aeration elements to improve cooling performance. Modern remote-support tools let our specialists assist in real time, whether for troubleshooting or scheduled maintenance.
thyssenkrupp guarantees operation of the cooling system for five years.
Reference: Phoenix Cement plant (Beckum)
At the Phoenix Cement plant in Beckum, thyssenkrupp Polysius installed the world’s first polytrack® eco clinker cooler, reusing existing infrastructure.
The plant operated at a nominal capacity of 1,400 t/day. Although the existing grate cooler was still functional, high maintenance effort and increasing alternative fuel rates of over 80% led to unstable operating conditions. To minimize investment costs, the upper housing, base frame and roll crusher were reused, while the housing was modified and elevated to integrate the longer cooler design.
The modernization was executed during the winter shutdown 2021/22 and completed within 38 days. The result was a significantly more stable and energyefficient cooling process. Heat consumption was reduced by up to 60 kcal/kg clinker, while electrical power demand dropped by 1–2 kWh/t. At the same time, the upgraded cooler enabled stable operation at alternative fuel substitution rates of over 90%.
Project Impact
Reduced specific heat consumption
Lower electrical power demand
Stable kiln operation at high alternative fuel rates
Reuse of existing structures, reduced CAPEX
Fast ROI
Why choose polytrack® eco?
With its advanced technology, the polytrack® eco offers cement producers a high-efficiency clinker cooling solution. Its innovative design, superior heat-recovery capabilities and low-maintenance structure make it an ideal investment for cement plants focused on sustainability and performance.
Upgrade your cement plant cooling system with the thyssenkrupp Polysius polytrack® eco – the future of energy-efficient clinker cooling.
Technical data
| Parameter | Value |
| Cooling efficiency | 76 % |
| Conveying efficiency | > 86 % |
| Clinker outlet temperature | 65 °C above ambient |
| Power consumption | < 4.5 kWh / t clinker |
| Roll crusher | 3–5 rolls, electromechanical drive |
| Crusher capacity | up to 9,000 t / day |