C o o l a x G r a t e Co Co o l e r
The COOLAX high efficiency grate cooler has greatly improved heat recuperation compared with traditional coolers. The efficiency of a grate cooler may be characterised in terms of cooler loss, this being the amount of clinker heat not recirculated to the pyroprocess. Traditional coolers have a loss of about 140 kcal/kg clinker. The COOLAX has a loss of only 95-100 kcal/kg clinker. clinker. In the heat recuperation zone (CFG zone) the cooling air is supplied direct to
the grate plates through a system of ducts and hollow beams instead of via an undergrate compartment as in conventional coolers. Only a small portion of the air enters the clinker bed from the undergrate compartment This is the sealing air. The CFG zone is divided into sectors supplied with cooling air from separate fans. The sectors are subdivided into smaller segments each with their own adjustable damper in the air supply system.
The drive
RFT zone
CFG zone
181 (C) 115 (B)
80 (E)
6 (D)
397 (A)
2.35 kg (G)
A. Clinker heat including dust B. Secondary air to kiln C. Tertiary air to calciner
Heat Values in Kcal/kg clinker
After the CFG zone comes the after-cooling zone with the Reduced Fall Through (RFT) grate. Here cooling air is supplied from undergrate compartments, as in conventional coolers, but the grate plates are identical to the ones in the CFG zone. The CFG system may in special cases be used throughout the entire cooler. The movable grate rows start at the cooler inlet, which prevents build up and reduces snowman tendencies. Heat recuperation is also improved this way.
The first grate is driven by a centrally positioned cylinder and the following grates by cylinders placed on either side of the coole r. The hydraulic drives consist of axial piston pumps with electro-hydraulic servo-adjustment of the oil flow to the cylinders which have built-in linear transducers. The system is controlled by a PLC.The pump units have built-in “swash” plates to regulate the oil flow and its direction. This ensures very smooth operation of the moveable grate rows and perfect grate control. The system is very reliable and maintenance costs are low. If preferred, a conventional mechanical drive 15 (F) can be supplied instead.
32oC D. Radiation losses E. Excess air F. Remaining clinker heat G. Cooling air per kg clinker
T he heat balance shows a high recuperat recuperation ion of of clinker heat result result ing i n effective coo cooling of the t he clinker and substantial fuel savings due to the high secondary air temperature.
Grate plates
The pressure drop across the CFG grate plate is higher than in traditional grate plates. This ensures perfect air distribution through the clinker bed and greatly improved heat recuperation. In the CFG zone the cooling air is in full contact with the inner surface of the grate plates which are thereby constantly cooled. The thermal load on the plates is therefore low. The plates are designed to prevent dust from falling through. Each pair of slots is shaped like an inverted T section. The principle is that air will always travel outwards through the slots while any dust entering the slots during a stoppage will be trapped in the labyrinth instead of falling through into the hollow girder below. A small amount of clinker dust will inevitably fall through the slots when the kiln and cooler are shut down. The dust is automatically cleared by the air flow at the next start-up.
CFG grate plate with three double rows of air slots for controlled air flow.
Flexible connections
The air distribution system consisting of ducts and hollow beams incorporates specially designed and highly reliable flexible connections between the fixed air ducts and the moving grate rows. Intermediate roller crusher
If the clinker is to be cooled to a very low temperature a special type of roller crusher may be fitted between the grate sections. The crusher reduces the size of the clinker and lumps of coating to attain faster and more effective cooling. Also retrofit
The COOLAX-CFG system is also well suited for upgrading existing grate coolers. In addition to the energy savings and improved operational performance a retrofit also allows increasing the throughput within the overall dimensions of the existing 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 perf ormance due to ! more stable high capacity kiln and cooler performance less dust circulation and no blowing through of cooling cooli ng 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 dimension s due to high specific grate load (up to ! small overall dimensions 2 60 t/m per 24 hours). !
T h e C OO OO L A X g r a t e c o o l e r i s available in three m ain versions :
SIZE SIZE SELECTION TION KEY EFFECTIVE EFFECTIVE GRATE AREA (M (M2)
LOAD ON GRATES ( T/M T/ M2 X 24H)
1. Flat bottom section with drag chains.
The size of cooler requird for a certain production cap acity and specific grate load can be read from the above diagram and below dimension table. The example shows the selection of size 1490 for capacity 5,500 t/ 24h and grate load 47 t/m2 x 24h 2. Bottom section with hoppers and sluices for external dust conveyor.
The permissible specific grate load depends on the required clinker temperature after the grate and will normally be within the range of 40 to 60 t/m2 x 24h.
3. Flat bottom section with roller crusher ahead of the last grate.
The main dimensions of the different types and sizes of COOLAX grate coolers appear fromt he above table and the sketches 1,2 and 3. Data in this brohure is only intended for preliminary project Planning. Manufacturer reserves the right to modify equipment details and/or specifications without notice. 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. Paulo-SP. CANADA: FULLER- F. L.SMIDTH CANADA LIMITED, lO.Thornmount Drive. Scarborough, Ontario MIB 3J4. FULLER -FL.SMIDTHCANADALIMITED.3300 Cavendish Boulevard. Montreal. Quebec H4B 2M8. CHILE: FULLER-TRAYLOR, FULLER-TRAYLOR, INC., Napoleon 3200. Of. 304. Las Condes, Santiago. FEDERAL REPUBLIC OF GERMANY: F. L.SMIDTH - FULLER GMBH, Rheinstern Haus, Emanuel Leutze 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: FLS Japan Ltd.,Togeki Building, 1-l.Tsukiji 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 Representative Office, Scite Tower. Room 1307,22 Jianguo Men Wai Dajie, Beijing 100004. SOUTH KOREA: FULLER INTERNATIONAL, INC.. Independent Sales Office, C.P.O. 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 Pasa Han. 92-94,80090 Giimussuyu, Istanbul. UNITED KINGDOM: F. L.SMIDTH FULLER LTD.. 17, Lansdowne Road, Croydon. CR9 2JT. LICENSEES/JOINT VENTURES: INDIA: Larsen &Toubro Ltd.. Cement Machinery Division, Powai Works, P. 0. Box 8901. Bombay 400072. FULLER - K.C.P. LTD., Ramakrishna Building, No. 2, Victoria Crescent. Madras 600105. FULLER - K.C.P. LTD., LTD., 220, Arun Chambers,}. 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.
