Cyclone Flash Coolers: Best possible performance for your application
Optimise your cooling processes, with our innovative Cyclone Flash Coolers
FLSmidth has precisely what producers need to optimise the calcination cooling process. With its high efficiency, flexibility and ease of operation, our Cyclone Flash Cooler has been a success since its debut in 1976. And thanks to our continual development of the system ever since, the Cyclone Flash Cooler is still at the forefront of technology. Flexible enough to meet future demands as well, this cooling solution can help plants stay in the lead for many years to come.
How the Cyclone Flash Cooler Works
Hot solids are introduced at the inlet gas duct to the Stage I (top) cyclones. It is subsequently cooled by lower temperature, countercurrent gas flow as it is continuously collected and passed down the other cyclone stages in the cooler.
An optimal solution
Cooler design has a strong influence on operational efficiency. Every FLSmidth cooler system is optimised for the individual situation in which it is to be used. FLSmidth’s decades of experience in this area enables us to deliver solutions that are ideal for each plant’s specific challenges.
These are some of the key factors that go into designing an optimal solution:
- Number of stages/cyclones
FLSmidth’s Cyclone Flash Cooler systems are equipped with up to five stages of cyclones. The number of stages is normally determined by the air/solids ratio and final product temperature target..
- Size of cyclones
The selection of cyclone sizes is a balance of having the smallest cyclone dimensions while maintaining the lowest overall pressure drop through the cooler. This is to minimise the induced draft (ID) fan power consumption – the most power consuming part of a pyro system. The size of cyclones relates to the maintenance of desired gas velocity criteria and efficiency.
Increasing the cooling cyclone dimensions reduces the pressure drop. But for any given cyclone geometry, stable cooler operation (without solids falling through the riser ducts) requires a certain minimum gas velocity.
Cyclone Flash Coolers — reliability, efficiency and ease of operation
- High reliability
- For you to get the most out of your coolers, they have to be able to withstand continual use and extreme stress. Our Cyclone Flash Coolers are made from durable materials, and constructed to outlast other cooling solutions on the market. This means less repair and maintenance downtime, improved throughput and better returns for your business.
- Optimal fuel and energy efficiency
- High energy costs have a way of eating into your profits. By optimising both fuel and energy efficiency, our Cyclone Flash Coolers empower your business to spend less, and net more.
- Unmatched flexibility
- When it comes to finding the right cooler for your business, the last thing you want is to try to force a round peg into a square hole. That’s why every one of our cooler system solutions is specially designed to be the perfect match for your unique situation and needs.
Advanced cooling technology to match your business
- High throughput capacity in a compact design
- Built with up to 5 cyclone stages
- Low pressure drop
- High solids collection efficiencies
FLSmidth coolers have been based on proven low pressure loss (LP) cyclones. The unique design of the LP cyclone ensures high thermal efficiency and low pressure drop while enabling a flexible and space-saving layout. LP cyclones have no horizontal surfaces on the inside for material to accumulate, thereby securing stable operation. The top stage has a special geometry to provide the lowest dust loss while maintaining low pressure drop. LP cyclones are not just for completely new coolers but may be individually fitted to upgrade existing coolers.
- Central pipes
Central pipes (thimbles) are standard in all cyclone stages to provide high separation efficiency.
- Sluice flaps and distribution boxes
To prevent gas from bypassing up through the material pipes between the cyclone stages, the pipes are equipped with sluice flaps (tipping valves) designed for full opening. Good meal distribution in the cyclone riser ducts is ensured by adjustable spreader plates in the distribution boxes.