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CROSS-BAR® COOLER
The Art of Cooling Clinker
Cross-Bar® Cooler
EFFICIENT COOLING WITH A
LOW TCO – NOW THAT’S COOL
You need three things from your cooler: high uptime, quick cooling, and the capability to
recoup as much heat as possible. With very low maintenance requirements and advanced,
R&D-led design, the Cross-Bar® cooler delivers on all fronts, giving you optimum cooler
performance with a low total cost of ownership.
KEY BENEFITS
No snowmen Robust cooler
High thermal recupteration Low maintenance
Hot air recirculation (up to 130 ⁰C) Energy efficient
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Cross-Bar® Cooler
Cross-bar® Cooler
The latest Generation Cross-Bar® Cooler, Less moving parts, less contact between clinker and machinery,
designed for maximum uptime and smart engineering that eliminates both agglomeration and
Snowmen. That’s what we’ve achieved with the Cross-Bar®
Cooler downtime causes lost productivity and lost profits. The cooler, which comes with the snowman-eliminating ABC Inlet
best way to reduce downtime is to choose a cooler that is as standard. To ensure maximum cooling efficiency, we use
designed to withstand the extreme conditions of the operation. self-adjusting mechanical flow regulators in essential zones to
The Cross-Bar® cooler is designed to be operational for 330 control the flow of ambient air through the clinker bed.
days a year, just like your kiln.
It’s efficient. It’s reliable. And it reduces both power and fuel
consumption, helping to curb carbon emissions. You can’t get
cooler than that.
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Cross-Bar® Cooler
PROVIDES ALL THAT YOU NEED
FROM THE COOLER
No more snowmen
When snowmen build up, the cooler goes down. While you can
‘fire-fight’ the beginnings of agglomeration, there comes a time
when your only recourse is to shut down the pyro system for a
clearout. Each time this happens you lose days of production and
consume excess fuel getting the pyro line back up to temperature
again. It’s expensive, stressful and unsustainable. No process can
afford repeated shutdowns over an extended period.
Destroying snowmen should not be part of your ‘business as
usual’. They should never be able to form in the first place. That’s
the basis of the ABC Inlet.
Better air flow
In the old-style moving grate coolers, air flow consistency
was disrupted by wear to the grates. With Mechanical Flow
Regulators (MFR) in essential zones, we have the opportunity to
optimise air flow to maximise cooling and recuperation efficiency.
The MFR acts as a flow limiter in places where more air flow
than needed typically passes through due to the lesser degree
of resistance, such as through the coarse clinker layer. It works
ABC™ Inlet
without operator intervention and gives you fuel savings and –
because less cooling air input is required to cool the clinker –
a substantial reduction in power consumption.
Air through Air through High bed Low bed
idle hole holes in resistance resistance
tongue
Air through
gaps Low ∆P High ∆P
MFR MFR
“Mechanical Flow Regulator automatically limits
desired airflow upon the varying clinker layer and Constant air flow irrespective of overgrate conditions
particle size without operator intervention.
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Cross-Bar® Cooler
No gaps, no loss of efficiency High thermal recuperation for optimum
efficiency
One of the main benefits of this approach is that the gradual
wear of the cross bars has no impact on cooler efficiency. By The heat from your cooling clinker is valuable. Not only does it
comparison, on moving grate cooler models, the grate plates hold the potential to reduce your fuel consumption in the kiln,
wear and create gaps between plates, which leads to inefficient it also opens up the possibility to burn more moist alternative
cooling and poor thermal efficiency – and all the additional fuels you might not otherwise consider viable. But you have a
problems that arise from clinker exiting the cooler without having limited window for capturing this heat. That’s why high thermal
cooled sufficiently. recuperation is a priority in the Cross-Bar® Cooler design.
Furthermore, because the Cross-Bar cooler is designed with no Upgrading your existing old cooler with the latest generation
moving grates and a well-proven seal arrangement, there’s also Cross-Bar cooler will provide you heat consumption savings in
no possibility for clinker to fall below the grates, which means you the range of 20 – 60 kcal/kg of clinker depending upon the age
no longer need a conveying system underneath. One less thing and type of your existing cooler.
to worry about.
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Cross-Bar® Cooler
Rapid quenching Moving bars, not grates – low maintenance
by design
Getting the clinker temperature down quickly avoids the C3S
reverting to C2S and impacting final cement strength. It also Replacing worn grates or carrying out gap management on
enables you to use that heat back in your kiln system. The Cross- grate type coolers are time-consuming exercises and an on-
Bar® Cooler is equipped with the ABC Inlet, which is designed going expense. In the Cross-Bar® cooler, clinker is moved through
for rapid quenching for faster and more even cooling. This the cooler using horizontal bars that operate in a shuttle motion
rapid cooling also ensures you maintain the optimum chemical across a number of lanes. This effectively conveys, mixes and
composition in the clinker, which both enhances the clinker shears the clinker and prepares it for efficient exposure to the
quality and gives you more flexibility with your cement product. cooling air.
The cross bars are raised about 90 mm above the grate line so
there is no contact with the grate itself, and the grate is further
Step 1. protected by a bed of clinker. This extends the grate life
considerably in comparison with the moving grate cooler models.
The number of lanes across the cooler width provides flexibility
to control red river formation. If you should see a red river, you
can simply slow the clinker transportation in the affected lane to
give the clinker more time to cool.
The Cross-Bar cooler is designed such that in most cases,
All lanes move forward you will only need one hydraulic cylinder per lane, reducing the
maintenance burden.
Step 2.
Every other lane moves backwards
The modular FLSmidth® Cross-Bar® cooler reduces installation
time and costs. It is manufactured to a high quality standard
and ensures attractive equipment delivery times.
Step 3.
Remaining lanes move backwards
Installation of FLSmidth Cross-Bar cooler inside existing
cooler housing
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Cross-Bar® Cooler
Helping you keep it cool
How does the ABC Inlet work? Designed and built by experts
Ordinary fixed inlets use air blasting to destroy agglomerations. The Cross-Bar® Cooler can be a completely new installation or
These air blasters are built into the side walls and back of the an upgrade for most existing coolers. This flexibility is possible
cooler inlet. But with a maximum blast radius of about half a thanks to the modular design, which can be tailored to fit most
metre, there’s a huge area in the centre of the inlet that the air footprints. As far as possible, our coolers are preassembled in
can’t reach. our workshop, ensuring rapid and hassle-free installation – often
manageable within a standard annual maintenance shutdown.
That’s where the snowmen can still form.
Maximise waste heat recovery
The ABC Inlet uses a patented in-grate design that pushes
compressed air up through the grates, blasting agglomerations. It’s not only in the first half of cooler where there is recuperated
Pressure sensors detect when build-up is starting to occur heat to be used. We can also integrate a waste heat recovery
and the automated blast control system reacts accordingly, system to your Cross-Bar Cooler so that you can use the excess
increasing blast frequency to disperse the clinker and prevent hot air elsewhere in your process. The processed air can also
further agglomeration. Smart, targeted and efficient. The result? be recirculated back to the cooler under compartment at ≤ 130
No snowmen. Ever. ⁰C to further boost the excess air heat content without affecting
cooler efficiency.
This solution is suitable for new installations and upgrades and
for partial or complete hot air recirculation, depending on your
needs. Hot air recirculation can help you meet strict emissions
requirements and maximise your waste heat recovery potential.
S I M P L E T O O P E R AT E S I M P L E T O M A I N TA I N
• Self-adjusting mechanical flow regulators • No moving grates
• No manual dampers • No clinker fall-through
• No internal piping or air beams • No side seals
• No sealing air fans • No spillage valves
• Few fans • No undergrate conveying system
• Easy replacement of wear parts
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C 03-21400-44-ENG V3
www.flsmidth-cement.com
Copyright © 2024 FLSmidth Cement. All Rights Reserved. FLSmidth is a (registered) trademark of FLSmidth A/S,
and FLSmidth Cement is authorized to use the trademark under a license agreement. This brochure makes no
offers, representations or warranties (express or implied), and information and data contained in this brochure are
for general reference only and may change at any time.
