FLSmidth Cross Bar Cooler

16 October 2018
We Drive Success through sustainable productivity enhancement
FLSmidth®
Cross-Bar® cooler
The information contained or referenced in this presentation is proprietary to FLSmidth and is protected by copyright law
NO. OF CROSS-BAR COOLERS
FLSmidth® 40
Cross-Bar® 30
20
Total installed capacity
cooler 10
0
~500
< 3000 3000-5999 6000-8999 > 9000 million tons
Capacity (TPD) clinker per year
More than 105

FLSmidth Cross-Bar
coolers sold since
2010
More than
350 38
Cross-Bar type coolers coolers in the size range
sold since 1997 6.000-12.000 tpd
4 16 October 2018 FLSmidth® Cross-Bar® cooler The information contained or referenced in this presentation is proprietary to FLSmidth and is protected by copyright law
FLSmidth®
Cross-Bar® cooler
Key Features
 Air Blast Controlled inlet

 Stationary, sealed grate
line
 Separate cooling and
conveying mechanism
 Horizontal design with
optimised transport
method
 Mechanical flow
regulators (MFR’s)
 Modular design
FLSmidth® Cross-Bar® cooler animation
Click to play the video

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ENERGY AVAILABILITY
FLSmidth®
Cross-Bar®
cooler
Consistent and high High reliability /
thermal efficiency availability
Setting the standard

in clinker cooling MAINTENANCE INSTALLATION
technology
Low, predictable Fast, low cost

maintenance installation
Consistent and
high thermal efficiency
Separate clinker conveying
and air distribution systems
 The gradual wear on the bars elements has
Air no impact on thermal efficiency or operation
distribution
system
The bars effectively convey,

mix and shear clinker layer
Separate clinker conveying
and air distribution systems
Cross-Bar® cooler Grate cooler
Fixed grate line, Cross bars convey clinker Moving grates, Grate plates convey clinker
 Wear only on Cross bars, it does not affect  Grate plate wears gradually
cooling efficiency  Inefficient cooling air via gaps
 High and consistent thermal efficiency  Reduced thermal efficiency,
 Higher fuel consumption
 Increased clinker exit temperature
Self-adjusting Mechanical Flow Regulator (MFR)
and low pressure drop air distribution plate
Limiting airflow to clinker bed, irrespective
of conditions above the grate line
 Optimized heat recuperation
 Reduced cooling air flow
 Avoiding red rivers
 Avoiding geysers/blow-throughs Air through

idle hole
Air through
holes in
Air through tongue
gaps
Typical heat and mass balance
Clinker cooler
Cooler Efficiency: 77,0 %
Tertiary air
with combustion air: 1.10 kg/kg cl. and ambient temp. 30 °C
0.650 kg/kg cl.
968 °C
Excess air Mid air 166.6 kcal/kg cl.
1.20 kg/kg cl. 0.0 kg/kg cl.
313 °C Secondary air
93.5 kcal/kg cl. 0.450 kg/kg cl.
1068 °C
Radiation 128.4 kcal/kg cl.
4.0 kcal/kg cl.
Clinker
Clinker
1.0 kg/kg cl.
1.0 kg/kg cl.
1450 °C
95 °C
383.0 kcal/kg cl.
17.7 kcal/kg cl.
Cooler thermal efficiency
Cooling air η = Hsec air + Hter air
2.30 kg/kg cl. Hclinker 1450°C
30 °C (ambient) η = (128.4 + 166.6) / 383.0
16.8 kcal/kg cl.
*reference to 0 °C
η = 77,0 %
Results achieved after Cross-Bar® cooler upgrade
at Rain Cement Ltd., India
Before After
Cross-Bar cooler
Cooler type Walchandnagar cooler
CB 10x41
Clinker production (tpd) 2864 2910
Grate loading (tpd/m²) 41.7 42.4
Actual cooler loss (kcal/kgcl) 149 110
Sp. Fuel consumption (kcal/kgcl) 765 735
Recuperation efficiency (%) 67 77
Sp. Power consumption (kWh/t)

4.9 4.4
Cooler fans + drives + Crusher
Clinker temp (°C) 117 + amb. 57 + amb.
Results achieved after Cross-Bar®
cooler upgrade in India
Before After
FLSmidth Cross-Bar
Cooler type Fons delta
CB 14x60
Clinker production 5250 t/d 6000 t/d
Cooler grate area ~131 m² 144.1 m²
Cooler grate loading 40.1 t/d/m² 41.6 t/d/m²
Sp. fuel consumption 738 kcal/kgcl 690 kcal/kgcl
Maintenance year 2013 - 2014 2016 - 2017 “Mechanical wear and tear
got reduced when compared
Maintenance cost 0.062 $/t 0.006 $/t to the previous cooler. Heat
recuperation efficiency also
increased”
in China
Before After
Cooler type Sinoma TC12102 CB 14x61
Grate area 119.3 141.8

5.8 5.5
Fixed speed Cooler fans + drives
at Jiangsu Helin Cement Co. Ltd., China
Before After
Cooler type Sinoma NC42359 CB 14x61
Grate area 141.1 148

5.8 5.2
Cooler fans + drives
High reliability /
availability
FLSmidth® ABC™ inlet (Air Blast Controlled)
 MFR cooling process supplemented by an

air blast released directly to the grates and
the clinker bed
 Eliminates snowmen and prevents dead

zones where traditional blasters in back wall
cannot reach
 Flexible control by blasting in zones with

variable intensity
 Ensures uniform clinker distribution
ABC™ inlet grate with internal valve
Blast air
when required
Normal
cooling air Blast air can reach
through MFR entire fixed inlet area
Other supplier’s Fixed inlet
- air blaster arrangement
 Side/back wall blaster
reach only 0.5m, can’t
reach the entire inlet zone
 Ineffective in eradicating
Back walls
the root cause for
agglomeration over grates
 Snowman formation exists
Ineffective blasting
Side Side
walls Blast air does not reach walls
these fixed inlet area
ABC™ inlet - proven design
 Operating experience since 2004
 Standard for all new coolers
 Ability to retrofit existing grate coolers
 Typical grate wear life of 3-5 years
ABC™ inlet
Results achieved after ABC™ inlet upgrade
at Titan Pennsuco, Florida, USA
Before After
Std. cooler loss (kcal/kgcl) 104 96
Secondary air temp (°C) 1046 1259
Tertiary air temp (°C) 937 1109
Clinker temp (°C) 137 116
Cooler drive speed (spm) 12.4 11.1
1/shift
Snowmen 0
(removed with water jet)
Protected stationary grate line
Static grate carrying the weight of the clinker Static clinker layer between bar and grate
Sealed grate line
Proven seal design, 20+ years experience No under grate spillage removal system
Horizontal design with
optimised transport method
Adjustable stroke
length of each drive
eliminate red rivers
Can still operate if

a cooler drive is
stopped
Step 1 Step 2 Step 3
All bars move forward. Every other lane Remaining lanes

moves backwards move backwards
Horizontal design with
optimised transport method
 Shuttle motion with Cross-Bar® cooler
independent, finite
control across the
cooler width
 Controllable clinker Drive 1 2 3 4 5 6 7

distribution Stroke length 200 260 300 300 300 260 200
Grate cooler
Red river Red river
Drive 1
Stroke length 130
Red river control
1450 °C
1250 °C
1100 °C
900 °C
700 °C
Grate cooler
500 °C
350 °C
200 °C
150 °C
90 °C
Cross-Bar® cooler
Heavy-duty Roll Breaker
highest reliability
 Crush very large lumps without stopping the
cooler
 Overload reversal for safety
 Low speed for long wear life: 3-5 years
 Rollout design for easy maintenance
 End- and mid-cooler applications available
Cases:
High cooler reliability achieved
RELIABILITY FACTOR [%] >99.5%
99,94 99,97 99,90 99,93 99,96 99,97 99,96 100,00 99,94 100,00 99,78 99,80 99,93 99,88 99,93
100,00 99,60 99,84 99,55
99,00
98,00
97,00
96,00
95,00
94,00
93,00
92,00
91,00
90,00
2011 2012 2013 2014 2015 2016
Source: FLSmidth O&M

Plant - A Plant - B Plant - C
Waste Heat Recovery with hot air recirculation
Flexibility in the location of hydraulic cylinders
Secondary +
Tertiary air
Mid air / WHR
Vent air
Fast, low cost
installation
Workshop pre-assembly and
container transport
Retrofit - less than 30 days
Modular design High flexibility for upgrades of existing coolers
Low, predictable
maintenance
Low, predictable maintenance
 Few wear components with known wear 2-piece Air Cross-Bar

rates Distribution
Plate with
 Typical wear life 3-5 years replaceable
upper part U-profile
 Simple and easy assembly
 Cast parts can be hand-carried
 When required, cooler can be emptied to

bar level with drives
First installation of FLSmidth® Cross-Bar® cooler
at Capitol, Texas, USA
8-grate wide rated for 2000 t/d
Actual wear part consumption
at Capitol, Texas, USA
Wear part cost:
Approx 0,006
USD/T Clinker over 5 years
Newly installed After 5 years in operation
Results achieved after Cross-Bar®
cooler upgrade at Capitol, Texas, USA
Before After
FLSmidth CFG (Controlled FLSmidth CB 8x61

Cooler type
Flow Grate) cooler (with ABC™ fixed inlet) cooler
37.5m² 44.2m² (+18%)

Cooler grate area
designed for 1816 t/d designed for 2000 t/d
Cooler inclination Inclined cooler Horizontal cooler
Standard cooler loss 118 kcal/kgcl 96 kcal/kgcl
> 900°C
< 700°C
Tertiary air temperature (common kiln hood) while
(separate take-off)
maintaining air temperature …and no unplanned kiln
outages to date since start-
Fan power consumption High Reduced (-20%) up in April 2010
The latest generation in
Cross-Bar® cooler technology
Resulting Benefits
 Superior reliability / availability
 Low operating cost
 Consistently high thermal efficiency
 Low, predictable maintenance The result :

one of the most competitive
 Fast, simple installation
and high performance coolers
 Great flexibility for retrofits on the market
 Suitable for hot air recirculation At an extremely attractive

installed cost
Cooler Optimization Support
1 process audit every year for 3 years after commissioning
FLSmidth® supports beyond the first
start-up
 Yearly audit with action plan to ensure:
 Optimized performance
 Knowledge of max possible performance
 Exchange experience with operators
Recent
improvements on
Cross-Bar® cooler
ABC™ inlet updates
 ABC inlet loading = 450 – 650 tpd/m²

 Sufficient cooling of clinker before it reaches Cross-Bar section
 Compartment split – dedicated fan for clinker drop zone
First cross bar
 To avoid build up between ABC™ inlet and first pusher face

 With reduced wing span to avoid emptying the first grates
Old Present
Updated cast parts and drive plate
 Bars elevated further above grate plate

 Increased insulation layer from 50 to 90 mm
 Lowered U-profile for better thermal protection
Single piece cross bar Split cast elevated cross bar
Updated & increased number of
Thermocouples units
 Elevated to ensure measurement in active bed
 Ensures early detection of high clinker bed temperature
 Monitors each lane, near first pusher phase
 Facilitates continued kiln operation even when one drive is hot and stopped
90 mm
35 mm
Old Present
Cooler interlock updates
 Limit operating speed changes in order to

reduce risk of operator error.
 Pre-set Cooler cascade table based on
production level:
 Air Blast program - also ties to ABC grate
temperature & compartment pressure
 Cooling air flow
 Drive speed
 Adjustable stroke length
 Early high grate temperature detection
 Auto stroke length reduction by 40%
 Cooler fan flow (first section) reduces
 Continue kiln operation even if one lane is stopped
Simplified Hydraulic system
Updated hydraulic system offers identical

performance with added benefits,
 Reduced number of hydraulic pumps &

motors
Updated HPU  Lower Installed power
 Fewer Hydraulic cylinders
 Smaller foot print
 Lower Power consumption
 Built-in standby provides redundancy

Previous HPU
16 October 2018
We Drive Success through sustainable productivity enhancement
SF™ Cross-Bar® cooler

upgrade
The information contained or referenced in this presentation is proprietary to FLSmidth and is protected by copyright law
SF™ Cross-Bar® cooler upgrade
Potential benefits:
 Greater throughput in a highly loaded SF™

Cross-Bar® cooler
 Fewer cast parts and longer lifetime for all

SF™ Cross-Bar® Coolers
 Improved control of clinker bed

 Increase in thermal efficiency
How is higher transport efficiency
achieved in the SF™ Cross-Bar® cooler upgrade?
Movable bars
All Movable bars

Stationary bar
SF™ cooler SF™ Cross-Bar® cooler
 One movable and one stationary bar  All bars are movable
 Each bar covers the width of 4 grates (1.2 m)  Each bar covers the width of 2 grates (0.6 m)
 Less transport efficiency of clinker  Higher transport efficiency
 Reduced cooler speed
 Life of wear parts extended by 30 to 50%
SF™
Cross-Bar®
cooler
upgrade
First SF™ Cross-Bar® cooler upgrade project
Ramliya cement plant, Egypt
Arabian Cement Co., Ramliya I plant, Egypt
 6000 t/d FLS plant
 Cooler: SF 4x6
 Kiln shutdown: 18 Jan 2010
 Kiln feed on: 11 Feb 2010
First SF™ Cross-Bar® cooler upgrade project (2010)
Ramliya cement plant, Egypt
Before upgrade 6150 tpd (22 spm) After upgrade +6800 tpd (12 spm)
Tasks in SF™ Cross-Bar® cooler upgrade
on an already installed SF cooler
 Replacement of bars with a new design  Installation of required hydraulic piping
 Mount new grate protection plates  New PLC program and supplementary
electrical parts are needed
 Divide the drive frame in two drive plates
(dismantling of the connections between  Upgrade on installed SF Cross-Bar
drive plates and original cylinder bracket) cooler can be completed in about 2-3
weeks period, or the above tasks can
 Replacement of cylinder brackets and inter- integrated during manufacturing before
modular straps cooler installation
 Installation of hydraulic blocks for flow
dividers and directional valves
(existing hydraulic cylinders reused)
Thank you
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16 October 2018

We Drive Success through sustainable productivity enhancement

More than 105

 Air Blast Controlled inlet

Click to play the video

Setting the standard

Low, predictable Fast, low cost

The bars effectively convey,

 Optimized heat recuperation

 Reduced cooling air flow

 Avoiding red rivers

 Avoiding geysers/blow-throughs Air through

Clinker production (tpd) 2864 2910

Grate loading (tpd/m²) 41.7 42.4

Actual cooler loss (kcal/kgcl) 149 110

Sp. Fuel consumption (kcal/kgcl) 765 735

Recuperation efficiency (%) 67 77

Sp. Power consumption (kWh/t)

Clinker temp (°C) 117 + amb. 57 + amb.

Clinker production 5250 t/d 6000 t/d

Cooler grate area ~131 m² 144.1 m²

Cooler grate loading 40.1 t/d/m² 41.6 t/d/m²

Sp. fuel consumption 738 kcal/kgcl 690 kcal/kgcl

Cooler type Sinoma TC12102 CB 14x61

Clinker production (tpd) 5000 6200

Grate area 119.3 141.8

Grate loading (tpd/m²) 41.9 43.7

Sp. Fuel consumption (kcal/kgcl) 751 730

Sp. Power consumption (kWh/t)

Clinker temp (°C) 110 + amb. 65 + amb.

Cooler type Sinoma NC42359 CB 14x61

Clinker production (tpd) 6300 6600

Grate area 141.1 148

Grate loading (tpd/m²) 44.6 44.6

Sp. Fuel consumption (kcal/kgcl) 766 750

Sp. Power consumption (kWh/t)

Clinker temp (°C) 110 + amb. 65 + amb.

 MFR cooling process supplemented by an

 Eliminates snowmen and prevents dead

 Flexible control by blasting in zones with

 Ensures uniform clinker distribution

 Operating experience since 2004

 Standard for all new coolers

 Ability to retrofit existing grate coolers

 Typical grate wear life of 3-5 years

Clinker production (tpd) 5300 5430

Std. cooler loss (kcal/kgcl) 104 96

Secondary air temp (°C) 1046 1259

Tertiary air temp (°C) 937 1109

Clinker temp (°C) 137 116

Cooler drive speed (spm) 12.4 11.1

Can still operate if

All bars move forward. Every other lane Remaining lanes

 Controllable clinker Drive 1 2 3 4 5 6 7

 Overload reversal for safety

 Low speed for long wear life: 3-5 years

 Rollout design for easy maintenance

 End- and mid-cooler applications available

Source: FLSmidth O&M

Modular design High flexibility for upgrades of existing coolers

 Few wear components with known wear 2-piece Air Cross-Bar

 Cast parts can be hand-carried

 When required, cooler can be emptied to

Wear part cost: