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Clinker Cooling

SF Cooler

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.

  • The basics
  • Steps
  • Maintenance

Key benefits

Potential 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 cross bars move forward together, and alternative lanes of newly designed 2-wide cross bars move together in the reverse stroke.

 

Because each cross bar covers only 2 grates instead of 4, you achieve more finite control across the width of the cooler. Furthermore, while your existing SF cooler has 6 moving and 6 stationary cross bars, the upgrade has only 6 moving cross bars along the length of a module.

 

In practice, this requires changing the cross bars 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 cooler untouched, and essentially only requires a change in cross bars and hydraulic system.

 

Typical steps to the upgrade process include:

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

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

Fast installation

Your SF 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 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 cross bars wear transport efficiency is reduced, causing the drive speed to increase. Therefore, to ensure maximum performance, cross bars must be replaced when worn. An upgrade increases the lifetime of cross bars, however, by X percent on average
  • Replace cross bars 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 cooler will reduce the heat recuperation when worn. Because of the independent clinker conveying and air distribution in an SF cooler, wear components have no effect on cooling efficiency

 

  • Sales

    Gregers Schmidt
    Cement Plant Projects & Machines
    Tel: +45 36 18 36 53
    Fax: +45 36 30 18 20
    gs@flsmidth.com

  • Upgrades

    Steen H. Iversen
    Cement Plant Upgrades
    Tel: +45 36 18 24 67
    Fax: +45 36 30 18 20
    shi@flsmidth.com

  • Services & Spare Parts

    Freddy Pedersen
    Spare Parts & Services
    Tel: + 45 36 18 26 28
    Fax: +45 36 30 18 20
    fhp@flsmidth.com

  • Main Office

    FLSmidth A/S
    Cement Technologies & Corporate Matters
    Vigerslev Allé 77
    2500 Valby
    DENMARK
    Tel: +45 36 18 10 00
    Fax: +45 36 44 11 46
    info@flsmidth.com

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Last updated 10.02.2011