- Superior reliability/availability
- Low, easy, predictable maintenance
- Consistently high thermal efficiency
- Low power consumption
- Fast, simple installation
- Highly flexible – can be used to upgrade most existing coolers
- Low civil, construction and operating costs
How it works
Similar to previous coolers from FLSmidth, which revolutionised the way clinker coolers are installed, operated and maintained, the FLSmidth Cross-Bar cooler features:
- A stationary grate line with no undergrate spillage or conveying system
- Separation of the conveying and cooling systems
- Air distribution plates with mechanical flow regulators
- Modular construction
- Bars that all are movable and reciprocate so as to optimise transport efficiency and enable horisontal installation
Quick and easy to install, the FLSmidth Cross-Bar cooler ensures maximum availability with minimum maintenance. And with a completely new size and structure of its modules, it makes for an ideal new cooler or upgrade.
Ideal for upgrades
With its modular design, the FLSmidth Cross-Bar cooler is flexible enough to enable complete or partial upgrades of most existing clinker coolers.
Upgrading is worth considering if you would like to:
- Eliminate bottlenecks
- Increase capacity and/or availability
- Decrease operating costs
Your installed SF Cross-Bar cooler can also be upgraded to achieve increased clinker transport, allowing greater throughput and more control of the clinker bed under heavily loaded conditions – all with fewer wear parts.
Read more about the SF Cross-Bar cooler upgrade here.
Contact your FLSmidth representative for an ROI calculation tailored to your facility. Read the SF Cross-Bar cooler upgrade leaflet or FLSmidth Cross-Bar cooler upgrade leaflet for more information on the upgrade process.
Calculate your ROI
Contact your FLSmidth representative for an ROI calculation tailored to your facility. Most plants show a return on investment within less than three years.
Read about how the FLSmidth Cross-Bar cooler is performing at Capitol Aggregates in San Antonio, Texas, and Arabian Cement Company in Ramliya, Egypt.
Five fundamental features
The following design features lay the foundation for the cement cooler’s superior performance:
1. Separate clinker conveying and cooling systems
Unlike other cooler designs, the FLSmidth Cross-Bar cooler separates the clinker conveying and air distribution systems. Reciprocating cross bars fitted above the stationary air distribution system effectively convey, mix and shear the clinker while at the same time preparing the clinker for efficient exposure to the cooling air. A further benefit to this separation is that gradual wear of the cross bars has no effect on cooler operation, and thermal efficiency stays high.
2. Stationary, sealed grate line
The FLSmidth Cross-Bar cooler has no movable grate plates. There is no fall-through of clinker, and no undergrate clinker conveying system or gap management of grates is required. A static layer of clinker protects the air distribution plates against heat and wear, so the plates are no longer a standard wear part.
A patented sealing design consisting of U- and C-profiles around the drive plates forms a dust trap, preventing clinker from entering the undergrate compartment. The sealing profiles extend throughout the entire cooler length, which means that during the reciprocating movement of the profiles, the ends are never exposed to wear by the clinker.
Five fundamental features
3. Self-adjusting mechanical flow regulators
Each air distribution plate is equipped with a mechanical flow regulator (MFR) that regulates the airflow via a self-adjusting orifice. This optimal principle of continuous airflow
regulation was invented by FLSmidth and helps optimise heat recuperation and distribution of air throughout the entire cooler. In turn, it enables fuel savings and few installed cooling fans.
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 based on simple physics and without operator intervention.
4. Modular concept
The FLSmidth Cross-Bar cooler is designed not only for completely new coolers, but also as an upgrade for most existing cement clinker coolers. To meet these requirements, the cooler is constructed as a modular system with units of varying size.
The cross bar cooler has a fixed inlet module followed by standard units, each measuring 1.2 or 1.8 meters in width and 3.0 or 4.2 meters in length. The standard units are preassembled in the workshop to ensure high quality and swift, simple installation.
Depending on the width (1.2 or 1.8 meters), a unit includes either 2 or 3 movable frames, each of 2 grates wide. Each movable frame rests on two roller bearings and includes a drive plate that penetrates the grateline via a slot that extends throughout the entire unit length. To form a whole clinker cooler, a number of units are put together lengthwise and widthwise, and the movable frames are connected along the length of the cooler.
Five fundamental features
5. Horizontal design with optimised transport method
The cooler’s new drive mechanism is designed to obtain optimal transport efficiency. Each line of movable frames in the cooler is operated by 2 or 4 hydraulic cylinders, depending on the cooler size, and has an independent drive. While all cross bars move in a shuttle motion, the movement of each line can also be separately adjusted to accommodate diverse clinker bed conditions.
High clinker transport efficiency allows horizontal construction in order to minimise installation height or maintain overgrate and kiln hood velocities in cooler upgrades – leading
to low cost of civil work and reduced dust recirculation.
In addition, an Air-Blast Controlled (ABC) fixed inlet as standard prevents the formation of snowmen and gives an optimal start to the cooling process with a more uniform clinker layer.
Service & Maintenance
Low, easy, predictable maintenance
The FLSmidth Cross-Bar cooler has few wear parts, meaning easy and economical maintenance. The cross bar and U-profile is one integral piece, held simply in place by wedges and pins and easily accessible from the overgrate 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 limited number of shifts to perform.