Multi-Movable Cross-Bar Cooler

Proven, reliable technology Flexible, horizontal modular design Reduced, predictable maintenance Consistently high thermal efficiency

Introduction

M U LT I - M O VA B L E C R O S S - B A R C O O L E R

MAIN FEATURES
Proven Cross-Bar technology High thermal efficiency Separate clinker conveying and air distribution systems Air distribution plates with mechanical flow regulators No sealing air No fall-through of clinker Modular design in cassettes Horizontal, stationary grate line Predictable maintenance Lower long-term maintenance costs Lower construction height Workshop quality Quick, easy installation Simple operation

Introduction
Beginning in 1997, the SF Cross-Bar cooler (SFC) revolutionised the way in which clinker coolers were installed, operated, and maintained. FLSmidth, the innovator of third generation cooler technology, is now pleased to offer substantially increased transport efficiency for this well-known and proven cooler design. The Multi-Movable Cross-Bar (MMC) cooler offers even greater possibilities of reducing maintenance and installation costs for both new and retrofit applications.

The principle
At the core of the MMC cooler is the proven technology of the original SFC: stationary grate line, air distribution plates with patented individual airflow regulation, patented sealing profiles, no undergrate spillage, modular construction, and separation of the conveying and cooling mechanism.

The MMC cooler comes in cassettes, similar to the modules in an SFC but without the supporting frame. The significant change in the MMC cooler is the way the drive mechanism is designed and functions. Each cassette has two drives built within and cross-bars over the grate line, but not all cassettes have a hydraulic cylinder. All cross-bars in the cassettes are now movable, and reciprocate so as to obtain significantly improved transport efficiency. This makes it possible to install the MMC cooler horizontally. Additionally, the drives can have individual stroke lengths and speeds to meet any special challenge in handling the clinker bed.

Maintenance
Compared to the original SFC, the MMC cooler has even fewer wear parts, resulting in easier and less costly maintenance. All

New installations for all capacities Complete or partial retrofit of existing coolers

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cross-bars are fitted with retainer brackets and are easily accessible from the over-grate area. During operation, a protective layer of clinker is maintained between the air distribution plates and the movable cross-bars, which ensures a long lifetime for the air distribution plates. Experience has shown that the maintenance of Cross-Bar coolers is very predictable and simple to perform. This makes for increased flexibility of maintenance planning and prevents critical path situations during a typical kiln overhaul. When maintenance is required, it will normally only take a couple of shifts to perform. It is usually assumed that the wear components will last a minimum of two full campaigns, but actual results have shown that even longer service life is possible.

1 2 3 4

C-profile U-profile Cross-bar Retainer bracket Wedge Pin

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M U LT I - M O VA B L E C R O S S - B A R C O O L E R

Multi-Movable Cross-Bar Cooler

Modular Cassette

Clinker Crusher (Alternative Heavy-duty Roll Breaker)

Uniform clinker size

Non-uniform clinker size

Flexible modular concept

When the MMC cooler was designed, it was not only planned for completely new coolers, but it was also targeted for retrofit solutions on any clinker cooler within its existing housing. To meet these requirements, the cassettes of the MMC cooler come in various widths and lengths. For a given cooler, the cassettes can simply be added side by side and end to end to handle any clinker production level. The increased clinker transport efficiency allows horizontal construction in order to minimise installation height or maintain over-grate and kiln hood velocities in retrofit cases. However, the slope of the cooler is also flexible to meet particular demands in an upgrade situation. In addition to new coolers and complete retrofits, the MMC cooler provides further flexibility by allowing partial retrofits on existing clinker coolers. A phased approach to upgrading an existing cooler is possible by retrofitting the recuperation zone first, which provides the optimum financial return, and then converting the rest of the cooler if later desired.

Air flow through holes in tongue Air flow through idle hole Air flow through gaps
Air distribution plate with mechanical flow regulator

Optimal cooling
In the MMC cooler, each air distribution plate is equipped with a Mechanical Flow

Regulator (MFR) which regulates the airflow via a self-adjusting orifice. This optimal principle of continous airflow regulation was invented by FLSmidth and can only be obtained in FLSmidth coolers. The MFR maintains a constant airflow through the air distribution plate and clinker bed, irrespective of clinker bed height, particle size distribution, or temperature. Should the restriction of airflow through one area of the clinker layer change, the MFR automatically compensates for the variations in restriction and maintains the desired airflow without intervention by the operator. The working principle of the MFR is based entirely on simple physics without any electrical controls. The MFR prevents the cooling air from tak-

ing the path of least resistance. This helps to optimise heat recuperation and distribution of air throughout the entire cooler, which in turn allows fuel savings and/or an increase in throughput. The air distribution plates are characterised by low pressure drop. The MFR system adds little to the pressure drop during normal operation due to the large orifice area. In this way, the undergrate pressure is considerably lower than in traditional air-beam style coolers thereby saving electrical energy. Air is supplied from one fan to each undergrate compartment which are formed when fitting the cassettes together side by side. The MMC cooler does not require air ducting in the undergrate compartments nor dampers for adjustment. The fixed grate line and innovative drive sealing arrangement prevent clinker fallthrough to the undergrate, and therefore there is no need for inefficient sealing air or undergrate spillage conveyors. Combined with the MFR technology, a reduced amount of cooling air and a minimum amount of cooling air fans are needed. In this way, the MMC cooler is much simpler to operate and maintain.

Multi-Movable Cross-Bar Cooler (MMC)

Production [MTPD] Size Grate area [m2] L [m] W [m] H [m] Grate load [MTPD/m2]

1100 1500 2000 2500 2900 3500 4100 4700 5400 6200 7000 8000 9000 10000 12000

7 x 37 7 x 49 9 x 49 9 x 61 9 x 73 11 x 73 11 x 85 14 x 75 14 x 87 14 x 99 18 x 87 18 x 99 18 x 111 23 x 99 23 x 123

25 34 44 55 66 79 92 105 121 138 158 180 202 231 286

13.8 17.4 17.4 21.0 24.6 24.6 28.2 25.4 29.0 32.6 29.5 33.4 37.0 33.7 40.9

3.10 3.10 3.81 3.81 3.81 4.41 4.41 5.46 5.46 5.46 6.88 6.88 6.88 8.53 8.53

8.5 8.5 8.5 8.7 8.7 8.7 8.7 9.0 9.0 9.3 9.3 9.6 9.6 9.6 10.0

42.5 43.9 44.7 45.0 43.7 44.0 44.2 44.5 44.4 44.9 44.1 44.3 44.5 43.3 41.9

Controlled impact section

The MMC cooler is installed with the proven controlled impact section with mechanical flow regulators (CIS/MFR). The CIS/MFR receives the clinker from the kiln, provides the quick initial clinker quench that

is critical to the overall performance of the rest of the cooler, and effectively distributes the clinker across the width to the downstream MMC cassettes. The MFRs in turn provide simple and optimal airflow distribution in this highly aggressive area. Additionally, an air blaster system is provided to minimise and prevent the formation of build-up (snowmen) in the inlet section. This ensures efficient and reliable operation of the cooler over time.

C5

CB-2

CB-4

CB-6

Summary
The Multi-Movable Cross-Bar cooler has evolved from the original third generation clinker cooler, the SF Cross-Bar cooler, to provide a highly flexible, reliable, and simple system that may be a complete new cooler installation for all capacities, or a complete or partial retrofit solution. The benefits of the MMC cooler are increased kiln run factor, low long-term maintenance costs, and optimal heat recuperation.

Simple to operate
Self-adjusting mechanical flow regulators No manual dampers No internal piping or air beams No sealing air fans Fewer fans

Simple to maintain
No moving grates No clinker fall-through No side seals No spillage valves No undergrate conveying system Easy replacement of wear parts

MAXIMUM AVAILABILITY

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interests.

DENMARK
www.flsmidth.com
Up-to-date addresses of worldwide subsidiaries and sales offices are available from our website

USA
FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Tel: +1 800-523-9482 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com

INDIA
FLSmidth Ltd. Capital Towers 180, Kodambakkam High Road Nungambakkam Chennai 600 034 Tel: +91 44-52 191234 Fax: +91 44-2827 9393 E-mail: indiainfo@flsmidth.com

FLSmidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail: info@flsmidth.com

11-05-251 www.zerodesign.dk