ROTARY KILN

Compax cooler

Installation, operation and maintenance

Approved date:

Created by: KAR-IN

Approved by:

Doc. No.: 37911-04-2.2

 ROTARY KILN
37911-04-2.2

Table of contents:
Page
1  General information ....................................................................................... 3 
2  Construction and operation principle ................................................................. 3 
2.1  Design of cooler ............................................................................................ 3 
2.1.1  The rotary section of cooler ................................................................. 3 
2.1.2  The stationary section of cooler ........................................................... 3 
2.2  Principle of operation ..................................................................................... 3 
3  Erection ...................................................................................................... 4 
3.1  Fitting the rotary cooler section ....................................................................... 5 
3.2  Fitting the stationary cooler section ................................................................. 6 
4  Maintenance ................................................................................................. 7 
4.1  Preventive maintenance (see the table on page 8) ............................................. 7 
4.1.1  Inspection during operation................................................................. 7 
4.1.2  Inspection during scheduled shutdown ................................................. 7 
4.1.3  Preventive maintenance, survey .......................................................... 8 
4.2  Replacement of cassettes ............................................................................... 8 
5  Appendices .................................................................................................. 9 

List of appendices:

Appendix 1 Side view of cooler .......................................................................................10 

Appendix 2 End view of cooler .......................................................................................11 
Appendix 3 End shield with burner doors etc. ...................................................................12 
Appendix 4 Top view of intermediate shell .......................................................................13 

List of figures:

Figure 1 Side view of cooler ...........................................................................................10 

Figure 2 End view of cooler ............................................................................................11 
Figure 3 End shield with burner doors etc. .......................................................................12 
Figure 4 Top view intermediate shell ...............................................................................13 

List of tables:

Table 1 Preventive maintenance, survey .......................................................................... 8 

In this manual, reference is made to the following instruction manuals etc.:

General safety regulations at sites of erection 32031

Assembly drawing
Lining drawing

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
37911-04-2.2

NOTE!
The present instruction manual is concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all
conceivable situations, which may occur during manufacture, installation, operation and
maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

1 General information
The COMPAX cooler is used to cool down the products from a rotary kiln for burning
of lime or similar materials.

2 Construction and operation principle

2.1 Design of cooler
The cooler consists of a rotary section and a stationary section. The stationary
section forms a shell around the rotary section.
2.1.1 The rotary section of cooler
See Appendices 1 and 2.
The rotary cooler section is fitted on the kiln through the flange (1).
Basically, the cooler section is made out of three concentric shells which in
combination forms the exit path of the material from the kiln and the
access route of the secondary air into the kiln.
The outer shell (2) is bolted to the flange (1). The intermediate shell (3)
and the inner shell (4) are supported by the spoke plates (5). The spoke
plates are placed in slots which allow them to take up the thermal
expansion which occurs due to the flexibility of the assembly. The
intermediate and the inner shell are furthermore prevented from rotating
relatively to the outer shell and axial movement by stop blocks (6) fitted on
the cooler flange (1).
The rotating cassettes (7) are attached to the inner shell. The cassette is a
wear part, and can be dismantled for replacement. See section 4.2.
2.1.2 The stationary section of cooler
The stationary cooler section consists of the stationary shell (8), the
support for tunnel (9), the tunnel (10), the end shield (11) with burner
doors (14)(15), the outlet casing (12) and the outlet (13).
The support structure carries the tunnel and the end shield (11).
The end shield (11) is provided with two doors (14) and (15), an
observation door (16), two inspection ports (17), and openings (18) and
(19) foreseen for TV-monitor, vacuum gauge, scanner and pyrometer,
respectively.
The outlet casing (12) is supported by the stationary shell (8) which is
separately supported to the foundation. The outlet (13) has two discharge
points, one for fine material and one for coarse material.

2.2 Principle of operation

The stationary cooler section surrounds the entire rotary section of the cooler
in order to reduce radiation loss and noise level. The secondary air is drawn

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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through the cooler in such a way that it passes between the stationary shell
and the rotary outer shell, with subsequent passage through the gap between
outer/intermediate and intermediate/inner shell, through the cassette and into
the kiln.
The hot material from the kiln drops into the cooler through the gap which is
formed by the kiln outlet and the end shield (11). The guide plates on the
cassettes (7) lead the material into the cassette. Due to the inclination and
rotation of the kiln, the material is led through the cassettes and into the zone
between the inner (4) and the intermediate shell (3).
Here the material is transported in upward direction, opposite the direction of
inclination of the kiln, and this is done by means of the flights on the inner and
intermediate shell. Simultaneously the material is lifted by the lifters on the
inner and intermediate shell during the rotation of the kiln, and drops through
the airflow which passes between the inner and intermediate shell, causing the
material to be cooled down.
Having passed the intermediate shell (3), the material drops into the space
between the intermediate and the outer shell (2). Here the material is
transported downward, i.e. in the direction of inclination of the kiln. The lifters
on outer and intermediate shell allow the material to fall through the passing
airflow for cooling. Eventually, the material is discharged into the shovel (23).
The shovel discharges the material into the outlet (13) of the cooler. The
shovel also collects any material spillage from the bottom of the stationary
shell (8) and discharges it to the outlet. In the cooler outlet there is a grate
through which the fine portion of the material is directed to a separate outlet.

3 Erection

Mandatory!
The instruction manual must be studied both by the client and by the
erection supervisor prior to commencement of erection work.
The directions outlined in instruction manual 32031 "General safety
directions at site of erection" must be strictly observed.

Following conditions applies to the procedures in this erection manual.

 the kiln flange is free and flush ground
 the noosering has not been erected on the kiln
 the kiln is fully available so that it can be turned and maintained in any arbitrarily
position during erection
 that the required crane capacity is available for lifting the preassembled rotary
cooler section from ground level to its position on the kiln.
 that the necessary space is provided in the buildings so that the rotary cooler
section can be fitted on the kiln in one piece after it has been assembled at ground
level.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
37911-04-2.2

3.1 Fitting the rotary cooler section

The rotary cooler section is assembled at ground level and fitted on the kiln in
one piece. The assembly operation may be carried out in the sequence
indicated below:
a) The flange (1) are divided and match-marked by the supplier. The bolt circle
diameter, the pitch between the holes, and that the flange is in plane must
be checked by the FLSmidth supervisor before and after the tack-welding of
the flange. (Offset flange parts before welding to prevent shrinking. See
assembly drawing.)
Subsequent to all-welding, the welds must be flush ground and the
plainness of the flange, 1/2000 of the flange diameter, must be checked. On
completion of the welding operation, the flange must be placed in horizontal
position, and securely supported, 300 mm above ground level in order to
make the bolt holes fully accessible.
b) Place the intermediate shell (3) on the flange. Use the erection tools welded
on the shell to adjust the gap between the shell sections before welding.
The gap should be approx. 1 mm. Before welding check that the roundness
of the shell is within 1/2000 mm of the diameter. Subsequent to welding
remove the erection tools.
c) Use the same procedure for inner shell (4) and outer shell (2). It may be
necessary to remove the intermediate shell from the flange in order to
provide access for welding of outer and inner shells.
d) Fit the outer shell (2) on the flange (1). Tighten the bolts by two sequences
to the torque level indicated on the assembly drawing. Do not tag weld the
bolts until the kiln has run for 48 hours. Place the intermediate (3) and
inner shell (4) on the flange and fit the matching stop blocks (6) on the
flange. All the bolts are to be fitted from the inside.
e) Fit the spoke plates (5) by sliding them from the top down.
To prevent deforming of the intermediate shell during transport, a cut in top
of intermediate shell (3) which is necessary to fit the spoke plates, is to be
made on site. See Appendix 4.
Bolts (29) through spoke plates must be loose fit and secured by welding.
f) It may be possible to at this point to install the rotating cassettes (7) on the
inner shell (4), and place the preassembled tunnel inside the rotary cooler
section, if the crane capacity necessary for lifting is available.
If so fit the four tunnel parts (10) on the horizontal leveled end shield (11).
Do not fit the stationary insulating cassettes (27) on the tunnel at this
point. Place the tunnel inside the rotating part of the cooler facing the
cooler flange. Make sure that the tunnel is fully supported around the full
length of the rotating cassette with 200 mm wood lathes.
Do not weld the stop plates at the end of the T-rails until the rotating
section has been fitted.
g) Check again the roundness of the shells and bolt the stiffening cross to the
outer shell (2).
h) Raise the assembled cooler section so that the flange (1) is aligned with the
kiln flange. Remove nut from the bolts for inner shell stop blocks.
i) Hoist the assembled cooler section up to kiln and attach the section to the
kiln with bolts. Use the torque levels indicated on the assembly drawing. If
the tunnel is preassembled and lifted together with the rotating section, the
nose ring on the kiln outlet must not be fitted at this time.

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 ROTARY KILN
37911-04-2.2

j) Fit the rotating cassettes (7) on the inner shell (4). Weld the stop plates at
the end of the T-rails.
k) Fit the shovels (23) on the outer shell. Check for radial distance between
shovel and outlet cone on the outlet section to be min. 75 mm.
l) All bolts in the bolted joints of the rotary cooler section must be secured by
welding on completion of erection work. The only exceptions are the joint
between the kiln flange and the cooler flange, and the joint between the
cooler flange and the outer shell. These two joints must be retightened to
the specified torque level during the initial shutdown and, subsequently,
they must be secured by welding.

3.2 Fitting the stationary cooler section

It is not advisable to start the installation of the stationary cooler section until
the rotary section has been fitted on the kiln.
The stationary cooler section can be fitted in the following sequence:
a) Attach the end shield (11) provisionally to the kiln outlet in such a way that
the risk of the frame getting into physical contact with the inner shell is
eliminated.
b) Cautiously lower the lower tunnel part (10) onto the rotary section. Fit the
left-hand (10), right-hand (10) and upper tunnel part.
c) Fit the tunnel support (9) and the end shield (11) to the tunnel.
d) Fit the burner doors (14)(15) and the observation door (16) on the end
shield.
e) Fit door locks (20), observation flap (17), sealing ring (21), retainer iron
(22) and cover plate (18) on the burner doors.
f) Install lining in doors and door frame as shown on lining drawings.
g) Fit the insulation cassettes (27). The insulation cassettes with guide plates
are to be fitted at 11 and 1 o'clock. The guide plates are supposed to lead
the material on the top of the tunnel forward to the intermediate shell.
h) Fit the parts of the stationary shell (8) on the appertaining supports.
i) Fit the 120° section of the outlet casing (12) on the stationary shell.
j) Fit the four remaining sections of the outlet casing (12) on stationary shell
(8).
k) Check the alignment of the tunnel relative to the rotary parts in six different
positions so that the clearances between the stationary insulation cassettes
(27) on the tunnel sections (10) and the rotating cassettes (7) are as
follows:
at the sides : 100 ± 10 mm
at the top : 90 ± 10 mm
at the bottom : 110 ± 10 mm
l) Check the alignment of the stationary shell to the rotary cooler section at
six locations as close to the outlet as possible. The radial alignment
tolerance must be within ± 10 mm.
m) Fit the outlet casing (12) to the tunnel.
n) Fit outlet (13) and grate on the 120° outlet casing (12).
o) Fit the sealing ring (26) so that a distance of approximately 50 mm is
assured between the ring and the outer shell (2). This will make it possible

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
37911-04-2.2

to adjust the sealing ring inwardly or outwardly respectively, depending on

whether kiln operation gives rise to generation of dust.

4 Maintenance
4.1 Preventive maintenance (see the table on page 8)
The plant management must ensure that routine maintenance procedures are
implemented in order to minimise the risk of:
 unscheduled shutdown
 breakdowns
 abnormal wear
4.1.1 Inspection during operation
1. Are there any coating in the cassettes? Use a lance to remove any
coating causing build-up on the cassettes.
2. Are there any broken bolts in the joint between the kiln flange and the
cooler flange? If the total number of broken bolts exceeds five, or two
bolts in a row, the kiln must be stopped for the reinstallation of bolts.
Bolts can be reinstalled through the arm hole at the inner shell by
pulling the cassette approx. 1 meter away from the kiln.
3. Are there any broken bolts in the joint between the cooler flange and
the outer rotary shell? If the total number of broken bolts exceeds ten,
or three bolts in a row, the kiln must be stopped for the reinstallation of
bolts.
4. Check that the rotary part of the cooler runs concentric around the
stationary part.
5. Check that all the bolts (29) in the spoke plates are intact. If any are
missing the kiln must be stopped immediately and new bolts must be
fitted.
4.1.2 Inspection during scheduled shutdown
1. If there are any broken bolts in the joints mentioned in subsection
4.1.1, items 2-5, they must be replaced.
2. If there are any broken bolts holding the shovel they must be replaced.
3. Check for and repair any cracks in the stop plates which hold in place
the cassettes.
4. Check and replace any missing stop blocks on the cooler flange (1)
holding the inner- and intermediate shell.
5. Check and repair any visible cracks on the three rotating shells,
particularly along flanges and weldings.
6. Check and repair the cooler flange (1) for any visible cracks around bolt
holes and along weldings.
7. Check and repair the kiln flange and suspension ribs for any visible
cracks around bolt holes and along weldings.
8. Check and repair the lining on the burner doors and the end shield.
9. Check and repair the lining on the kiln flange and the alligator nose
ring.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
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4.1.3 Preventive maintenance, survey

Replacement of

Functional test
Status check
adjustments
Inspection,
Lubrication
Job
Pos. Equipment description

Cleaning
designation

spares
00 Compax A A 2A S,T

02, 01 Outer shell and bolts for flange 2A M,T

03, 06 Intermediate shell and stop block 2A M,T

04, 06 Inner shell and stop block 2A M,T

07 Rotary cassette and stop plates 2A 2A S,T T

11, 14 Lining of burner door, end shield,

2A M,T
15, 16 kiln flange and alligator ring

13 Outlet grate S 2A M,T

23 Shovel and bolts 2A M,T

29 Bolts for spoke plates 2A M,T

Table 1 Preventive maintenance, survey

Explanation:

D = every 8 hours operation A preceding to a letter in the table indicates

S = weekly the frequency of the activity in question.
M = monthly (Example: 2M means twice a month)
A = annually
T = see text in instruction manual

4.2 Replacement of cassettes

The cassettes (7) are considered a wear part and can be replaced in the
sequence outlined below:
a) Turn the kiln so that the defective cassette is positioned at the centre of the
blanked-off door (24)

Mandatory!
The kiln rotation must be prevented by braking the barring motor and
through the insertion of wedges of hard wood between kiln tyre and
supporting rollers.

b) Remove the blanked-off door (24)

c) On the inner shell (4) cut off the fitting which is used to retain the cassette
(7). Pull the cassette out through the hole specifically provided for this
purpose.
d) Remove material from the inner shell and the neighboring cassettes. Fit the
new cassette (7) which has been provided with a lining. Then, at the outlet
end, on the inner shell (4) fix the fitting by welding to ensure fixation of the
cassette (7).
e) Refit the blanked-off door (24).

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
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f) Remove the wedges between kiln tyre and supporting rollers and disengage
the barring motor.

5 Appendices
See next pages.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 ROTARY KILN
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Appendix 1 Side view of cooler

01. Cooler flange 10. Tunnel

02. Outer shell 11. End shield
03. Intermediate shell 12. Outlet casing
04. Inner shell 13. Outlet
05. Spoke plates 23. Shovel
06. Stop blocks 26. Adjustable ring for air inlet
07. Rotating cassette 27. Insulation cassette
08. Stationary shell 28. Embossed plate
09. Support for tunnel 29. Bolts for spoke plate
Figure 1 Side view of cooler

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
37911-04-2.2

Appendix 2 End view of cooler

05. Spoke blocks 13. Outlet

07. Rotating cassette 23. Shovel
09. Support for tunnel 24. Blanked-off door
10. Tunnel 25. Inspection door
11. End shield 27. Insulation cassette
12. Outlet casing
Figure 2 End view of cooler

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Appendix 3 End shield with burner doors etc.

11. End shield 18. Cover plate

14. Burner door, left 19. Branch with coupling
15. Burner door, right 20. Door lock
16. Inspection door 21. Sealing ring for burner
17. Observation flap 22. Retainer bar
Figure 3 End shield with burner doors etc.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
ROTARY KILN, Compax cooler
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Appendix 4 Top view of intermediate shell

Cut to be made
at site

Figure 4 Top view intermediate shell

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.