Coolax Grate Cooler

The COOLAX high efficiency grate coolerhas greatly improved heat recuperation com-pared with traditional coolers.

The efficiency of a grate cooler may becharacterised in terms of cooler loss, thisbeing the amount of clinker heat not recircu-lated to the pyroprocess. Traditional cool-ers have a loss of about 140 kcal/kg clinker.The COOLAX has a loss of only 95-100kcal/kg clinker.

In the heat recuperation zone (CFG zone)the cooling air is supplied direct to

the grate plates through a system of ductsand hollow beams instead of via an undergratecompartment as in conventional coolers. Onlya small portion of the air enters the clinkerbed from the undergrate compartment This isthe sealing air.

The CFG zone is divided into sectors sup-plied with cooling air from separate fans. Thesectors are subdivided into smaller segmentseach with their own adjustable damper in theair supply system.

After the CFG zone comes the after-coolingzone with the Reduced Fall Through (RFT)grate. Here cooling air is supplied fromundergrate compartments, as in conventionalcoolers, but the grate plates are identical to theones in the CFG zone. The CFG system mayin special cases be used throughout the entirecooler.

The movable grate rows start at the coolerinlet, which prevents build up and reducessnowman tendencies. Heat recuperation is alsoimproved this way.

The driveThe first grate is driven by a centrally posi-tioned cylinder and the following grates bycylinders placed on either side of the cooler.

The hydraulic drives consist of axial pistonpumps with electro-hydraulic servo-adjustmentof the oil flow to the cylinders which havebuilt-in linear transducers. The system is con-trolled by a PLC.The pump units have built-in“swash” plates to regulate the oil flow and itsdirection.

This ensures very smooth operation of themoveable grate rows and perfect grate control.The system is very reliable and maintenancecosts are low.

If preferred, a conventional mechanical drivecan be supplied instead.

The heat balance shows a high recuperation of clinker heat resulting in effective cooling of the clinker andsubstantial fuel savings due to the high secondary air temperature.

Grate platesThe pressure drop across the CFG grate plateis higher than in traditional grate plates. Thisensures perfect air distribution through theclinker bed and greatly improved heat recu-peration.

In the CFG zone the cooling air is in fullcontact with the inner surface of the grateplates which are thereby constantly cooled.The thermal load on the plates is thereforelow.

The plates are designed to prevent dust fromfalling through. Each pair of slots is shapedlike an inverted T section. The principle isthat air will always travel outwards throughthe slots while any dust entering the slots dur-ing a stoppage will be trapped in the labyrinthinstead of falling through into the hollow girderbelow.

A small amount of clinker dust will inevitablyfall through the slots when the kiln and coolerare shut down. The dust is automaticallycleared by the air flow at the next start-up.

CFG zone RFT zone

181 (C)

115 (B)

397 (A)6 (D) 80 (E)

CFG grate plate with three double rows of air slots for controlled air flow.

A. Clinker heat including dustB. Secondary air to kilnC. Tertiary air to calciner

Heat Values in Kcal/kg clinker

D. Radiation lossesE. Excess airF. Remaining clinker heatG. Cooling air per kg clinker

2.35 kg(G)

32oC

15 (F)

Flexible connectionsThe air distribution system consisting ofducts and hollow beams incorporatesspecially designed and highly reliableflexible connections between the fixed airducts and the moving grate rows.

Intermediate roller crusherIf the clinker is to be cooled to a very lowtemperature a special type of rollercrusher may be fitted between the gratesections. The crusher reduces the size ofthe clinker and lumps of coating to attainfaster and more effective cooling.

Also retrofitThe COOLAX-CFG system is also wellsuited for upgrading existing grate coolers.

In addition to the energy savings andimproved operational performance aretrofit also allows increasing the through-put within the overall dimensions of theexisting cooler casing.

The high-efficiency COOLAX features! Fuel savings of 30-40 kcal/kg clinker! 30% less cooling air and 40% less air to be dedusted! low overall power consumption! effective and consistent cooling of clinker! more stable high capacity kiln and cooler performance due to

less dust circulation and no blowing through of cooling air! low maintenance costs due to minimum wear on grate plates

and movable parts! less red river tendency due to the Controlled Flow Grate

system! less snowman tendency! less falling through of clinker! small overall dimensions due to high specific grate load (up to

60 t/m2 per 24 hours).

Data in this brohure is only intended for preliminary project Planning. Manufacturer reserves the right to modify equipment details and/or specifications without notice.

2. Bottom section with hoppers and sluices for external dust conveyor.

3. Flat bottom section with roller crusher ahead of the last grate.

The size of cooler requird for a certain production capacity and specificgrate load can be read from the above diagram and below dimensiontable. The example shows the selection of size 1490 for capacity 5,500 t/24h and grate load 47 t/m2 x 24h

The permissible specific grate load depends on the requiredclinker temperature after the grate and will normally bewithin the range of 40 to 60 t/m2 x 24h.

The main dimensions of the different types and sizes ofCOOLAX grate coolers appear fromt he above table and thesketches 1,2 and 3.

1. Flat bottom section with drag chains.

The COOLAX grate cooler isavailable in three main versions :

SIZE SELECTION KEY EFFECTIVE GRATE AREA (M2)

LOAD ON GRATES ( T/M2 X 24H)

DENMARK: F. L.Smidth & Co. A/S. Vigerslev Allé 77. DK-2500 Valby Copenhagen.USA: FULLER COMPANY, 2040 Avenue C, Bethlehem, Pennsylvania. 18017-2188.F. L.SMIDTH & FULLER SUBSIDIARIES: AUSTRALIA: FULLER -F. L.SMIDTH (PACIFIC) PTY. LTD. Level 4.156 Pacific Highway, Greenwich, N.S.W.2065. BRAZIL: F. L.SMIDTH, COMÉRCIO E INDÚSTRIA LTDA. Rua Nebraska.443. Brooklin Paulista-CEP 04560. Caixa Postal 3506,01051 São Paulo-SP.CANADA: FULLER- F. L.SMIDTH CANADA LIMITED, lO.Thornmount Drive.Scarborough, Ontario MIB 3J4. FULLER -FL.SMIDTHCANADALIMITED.3300Cavendish Boulevard. Montreal. Quebec H4B 2M8. CHILE: FULLER-TRAYLOR, INC.,Napoleon 3200. Of. 304. Las Condes, Santiago. FEDERAL REPUBLIC OFGERMANY: F. L.SMIDTH - FULLER GMBH, Rheinstern Haus, EmanuelLeutze Strasse 17,4000 Düsseldorf 11. FRANCE: F. L.SMIDTH- FULLER S.A.. 2/4 rueVincentvan Gogh. 93364 Neuilly-Plaisance Cédex. ITALY: F.L.SMIDTH&C.ITALIANA S.r.L.,Via Aterno. 26,1-66020 S. Giovanni Teatino (CH). JAPAN: FLSJapan Ltd.,Togeki Building, 1-l.Tsukiji 4- chome, Chuo-ku, Tokyo 104. Postal address:Kyobashi P.O. Box 78,Tokyo 104-91. MEXICO: F. L.SMIDTH-FULLER MEXICO,S.A. DE C.V., Ave. Campos Eliseos 385,Torre “B”, Primer Piso, Chapultepec Polanco,

11560 Mexico City, D.F. P.R. CHINA: F. L.Smidth & Co. A/S. Beijing RepresentativeOffice, Scite Tower. Room 1307,22 Jianguo Men Wai Dajie, Beijing 100004.SOUTH KOREA: FULLER INTERNATIONAL, INC.. Independent Sales Office,C.P.O. Box 2016, Hwa-Shin Building, 3rd Floor, 82 1-KA Bongrae-Dong, Choong-Ku,Seoul. SPAIN: F. L.SMIDTH & CIA ESPANOLA, S.A., Carretera de La Coruna,km. 17.8.28230 Las Rozas (Madrid). TURKEY: F. L.Smidth & Co. A/S.. Liaison Office,c/o Trakmak.Traktörve Makine Ticaret Ltd. Sirketi, Ismet Inödü Cad., Mithat PasaHan. 92-94,80090 Giimussuyu, Istanbul. UNITED KINGDOM: F. L.SMIDTH -FULLER LTD.. 17, Lansdowne Road, Croydon. CR9 2JT. LICENSEES/JOINTVENTURES: INDIA: Larsen &Toubro Ltd.. Cement Machinery Division, PowaiWorks, P. 0. Box 8901. Bombay 400072. FULLER - K.C.P. LTD., RamakrishnaBuilding, No. 2, Victoria Crescent. Madras 600105. FULLER - K.C.P. LTD., 220, ArunChambers,}. Dadaji Road.Tardeo, Bombay 400 034. FULLER - K.C.P. LTD., 10-E,Annapurna Apartments, 68. Ballygunge Circular Road, Calcutta 700 019.FULLER- K.C.P. LTD., 1009. Tolstoy House. 15 Tolstoy Marg., New Delhi 110001.SOUTH AFRICA: FULLER- F. L.SMIDTH (PTY) LTD., 363 Rivonia Boulevard.Rivonia, P. 0. Box 1537, Rivonia 2128.