The grate cooler at Capitol Aggregates in San Antonio was performing well with few maintenance issues – but Capitol had an eye to the future and wanted to increase capacity ahead of a rebound in the cement market. Installed during a routine shutdown, FLSmidth’s Cross-Bar® Cooler put the Texas-based company in the position to boost capacity by 10% while improving thermal efficiency and cutting power consumption.
While the existing FLSmidth CFG Cooler at Capitol Associates was reliable, it would not have supported significant production increases. After installing the FLSmidth Cross-Bar® Cooler, Capitol experienced major improvement in both thermal efficiency and power consumption: an increase in tertiary air temperature to over 900 degrees Celsius, and a reduction in fan power by 20%. And the cooler vent system is running with only about half the excess air as before.
FLSmidth examined the plant layout with 3D modelling before deciding how to proceed and found the back portion of the old cooler casing could be re-used. The 3D modelling pointed out interferences that might hamper the project so FLSmidth could modify some of the equipment in advance.