Forced Draft Cooler

The Forced Draft Cooler is basically gas to air heat exchanger. These are especially suitable for Heat
and mass transfer where water cannot be used economically as cooling media. This is particularly
suitable for Sponge Iron Kilns.

Here the flue gases are made to pass over the tubes and fresh atmospheric air is passed through
the tubes by FD Fans. The heat exchange takes place between the cooling media (Air) and the gas
via convection. The flow of hot gases and the cooling media are perpendicular to each other to have
maximum heat exchange efficiency.

The FD Cooler is made of multiple bank tube bundles stalked one over the other. The Hot flue gases
enter the system at the top and after loosing its heat to the cooling media (Air) in the process,
enter the dust collector (ESP or Bag Filters).

The dust particles in the flue gases are collected in the hopper mounted under the FD cooler and are
discharged via Rotary Air Lock. The temperature of the Flue Gases coming out of the FD Cooler are
monitored and controlled by injecting a small qty of bleeding air after the Cooler.
We have supplied these FD Coolers for several 50TPD and 100TPD sponge iron Plants.

Forced Draft Cooler is majorly used for reducing the temperature at the places where equipment having
high temperature cannot be used. An air-to-air heat exchanger is used. With the use of banks of tubes
placed vertically and horizontally, hot gas with average velocity of 20m/s is passed through inside or outside
of the tubes. If cool air is passed, then it should be passed with a velocity of 6-7 m/s. Moreover, the Forced
Drafter Cooler supplied by us is primarily preferred as it consumes less power.

Type of FD Cooler :

 FD Cooler of Vertical Circular Tube type :- In this type of cooler, tubes are fixed on top and
bottom tube sheets. Hopper is incorporated for dust collection. It may not be necessary to operate all
the fans at a time. One or number of fans can be put on or off depending on the outlet temperature of
the cooler thus saves power.

 FD Cooler of Horizontal Flat Tube type :- In this type, flat tubes are placed horizontally. Because
of the flatness more heat transfer area is exposed to the hot gas which is made to pass along the
outside of the tubes. Therefore effectiveness of the heat transfer area is more in this case. Since
outside is accessible it is also easy to clean. Tubes are also removable and therefore replacement, if
necessary, is easy.