SF™ Cross-Bar® cooler

A surprisingly simple upgrade gives your SF™ cooler increased clinker transport, allowing greater throughput and more control of the clinker bed under heavily loaded conditions – all with fewer wear parts.

SF cooler
  • The basics
  • Steps
  • Maintenance

Key benefits

  • Greater throughput/capacity with the same grate area
  • More cooler control under heavily loaded conditions
  • Fewer cast parts for low, easy, predictable maintenance
  • Longer lifetime of wear parts
  • Improvements in thermal efficiency and power consumption
  • Fast, simple installation
  • Attractive investment level

How it works

The key change involves an upgraded transport mechanism. A shuttle drive motion is used, where all crossbars move forward together, and alternative lanes of newly designed 2-wide crossbars move together in the reverse stroke.

Because each crossbar covers only 2 grates instead of 4, you achieve more finite control across the width of the cooler. Furthermore, while your existing SF™ Cross-Bar® cooler has 6 moving and 6 stationary crossbars, the upgrade has only 6 moving crossbars along the length of a module.

In practice, this requires changing the crossbars and dividing the drive frame into 2 separate, independent drive plates. By increasing the clinker transport efficiency with the same hydraulic flow volume and with fewer strokes, you achieve greater throughput without enlarging the grate area. And since the drive now moves more slowly, the lifetime of wear parts is also extended.

How it’s done

The upgrade is achieved with the majority of your SF™ Cross-Bar® cooler untouched, and essentially only requires a change in crossbars and hydraulic system.

Typical steps to the upgrade process include:

  • Replace crossbars with a new design
  • Mount new grate protection plates
  • Divide the drive frame into 2 drive plates (dismantle the connections between drive plates and original cylinder bracket)
  • Replace cylinder brackets and inter-modular straps
  • Install hydraulic blocks for flow dividers and directional valves (existing hydraulic cylinders reused)
  • Modify hydraulic piping as required
  • Install new PLC program and supplementary electrical parts

A project includes a thorough review of all existing SF Cross-Bar cooler equipment from both a mechanical and process perspective to ensure a successful upgrade.

Fast installation

Your SF Cross-Bar cooler can be upgraded within an estimated 2-3 weeks – in other words, during a normal maintenance stop. And, no heavy equipment is needed to carry out the changes.

Tips

Although upgraded SF Cross-Bar coolers require even less maintenance than traditional SF Cross-Bar coolers, both demand a maintenance strategy. Please note the following:

  • Choose either periodic preventive maintenance or condition-based preventive maintenance for cooler fans
  • As the crossbars wear transport efficiency is reduced, causing the drive speed to increase. Therefore, to ensure maximum performance, crossbars must be replaced when worn.
  • Replace crossbars when a cross section exists where the length of the lowermost surface is reduced by more than 20% 
  • Mechanical flow regulators do not wear, and maintenance is limited to a yearly inspection and occasional cleaning
  • No mechanical wear components in an SF Cross-Bar cooler will reduce the heat recuperation when worn. Because of the independent clinker conveying and air distribution in an SF Cross-Bar cooler, wear components have no effect on cooling efficiency
SF cooler maintenance
SF cooler maintenance