■ Mechanical air-flow control

■ No moving grates

■ Optimised air distribution

■ Reduced installation time and costs

SF Cross-Bar Cooler

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Innovative featuresCross-bars, separate clinker conveying device The SF Cross-Bar Cooler has no movablegrate plates. There is no fall-through ofclinker and no undergrate clinker conveyingsystem is required. A static layer of clinkerprotects the air distribution plates againstheat and wear, so the plates will remain inservice for a long time. Reciprocating cross-bars fitted above the stationary air distribu-tion system effectively convey, mix andshear the clinker while at the same timepreparing the clinker for efficient exposureto the cooling air. The cross-bars workaccording to the same principle as recipro-cating cooler grates, but gradual wear ofthe cross-bars has no effect on cooler opera-tion and thermal efficiency, as the conveyingand air distribution systems are separate.

• High thermalefficiency

• High secondary and tertiary airtemperature

• Stationary airdistribution plates

• Clinker conveying and air distributionsystems are separated

• No sealing air• Air distribution plates

with mechanical flowregulators (MFR)

• Reduced electricalpower consumption

• No thermal expansionof grate line

• Long service life of airdistribution plates

• No fall-through ofclinker

• No undergrate clinkerconveying system

• Easy operation• Easy maintenance• Easy installation• Modular design

Main features

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IntroductionThe SF (Smidth – Fuller) Cross-Bar Cooler isthe result of a major and intensive develop-ment effort. It is well known that the per-formance of a traditional cooler dependsupon the mechanical condition of the grateline. The overall aim has been to develop acooler where the conveying and air distribu-tion systems are separate, sealing air is elim-inated and the distribution of air is opti-mised for all modes of operation. At thesame time, the cooler should be easy andquick to install, while attaining maximumavailability and minimum maintenance. The SF Cross-Bar Cooler has achieved allthese goals by means of the followinginnovative features: Cross-bars as conveyingdevice, a stationary air distribution systemwith mechanical flow regulators (MFR) foreach grate plate and a modular design.

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The cross-bars are held in position by retain-er brackets. All wear parts are easy to installand replace.

Mechanical flow regulators andair distribution platesMechanical flow regulatorIn the SF Cross-Bar Cooler each air distribu-tion plate is equipped with a MechanicalFlow Regulator (MFR) which regulates the air-flow to each plate via a self-adjusting orifice.

The MFR maintains a constant airflowthrough the air distribution plate and clink-er bed, irrespective of clinker bed height,particle size distribution, temperature, etc.

If for some reason the restriction of air-flow through the clinker layer changeslocally, the MFR automatically compensatesfor the variations in restriction and main-tains the desired airflow.

The MFR working principle is entirelybased on simple physical laws without anyelectrical controls.

The MFR prevents the cooling air fromtaking the “path of least restriction”. Thishelps to optimise heat recuperation and dis-tribution of air throughout the entire gratecooler, which in turn allows fuel savingsand/or an increase in throughput.

Air distribution plateThe air distribution plates of the SF Cross-Bar Cooler are characterised by low pres-sure drop. The MFR system adds little to thepressure drop during normal operation, dueto the large orifice area. So the undergratepressure is considerably lower than in tradi-tional coolers, which in turn saves electricalenergy.

Air is supplied from one fan to eachundergrate compartment, established whenfitting the modules side by side together.

The SF Cross-Bar Cooler has no internalducting within the undergrate compart-ments.

The protective layer of static clinkerbetween the cross-bars and the air distribu-tion plates prevents wear of the air distribu-tion plates.

Modular conceptThe entire SF Cross-Bar Cooler is construct-ed as a modular system with a fixed inletmodule followed by standard modules (1.3m wide x 4.2 m long or 4 x 14 air distribu-tion plates). The standard modules are pre-assembled in the workshop to ensure highquality and swift and easy installation. Eachmodule includes a movable frame activatedby a hydraulic cylinder. The movable frameis guided by four linear guide bearings andhas two drive plates.

The drive plate penetrates the grate linevia two slots, which extend throughout theentire module length. On top of the driveplates a patented sealing profile forms adust trap, preventing clinker from enteringthe undergrate compartment and, conse-quently, eliminating the need for a dustspillage conveyor.

The sealing profiles extend throughoutthe entire cooler length, which means that

Air-flow through holes in tongue

Air-flow through idle hole

Air-flow through gaps

Mechanical flow regulator

Reciprocating cross-bars above stationary clinker layer

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Modular cooler conceptOne standard module

SF Cross-Bar Cooler

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Workshop quality

Easy maintenance

Modular construction

Air distribution plates with Mechanical Flow Regulator (MFR)

Innovative air distribution

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during the reciprocating movement of theprofiles, the ends are never exposed towear by the clinker.

Because the standard modules consist ofstandard mechanical components, veryattractive equipment delivery times can beoffered. The modular cooler concept allowsdifferent configuration patterns for variouscooler sizes, depending on production level,clinker temperature requirements, etc.

Process improvementsThe SF Cross-Bar clinker cooler concept fea-tures improved thermal efficiency, resulting

in high secondary and tertiary air tempera-ture, which lowers overall heat consump-tion. High thermal efficiency and reducedpower consumption are maintainedthroughout the life of the cooler, irrespec-tive of the wear on the conveying system.

This is due to the:• impact zone with stationary inlet module• compartment aeration without inefficient

sealing air• optimised air distribution throughout the

service life of the cooler, ensured by themechanical flow regulators

Uniform clinker size Non-uniform clinker size

Preassembled

modules with

sideframes

(optional supply)

at construction site.

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The SF Cross-Bar Cooler

Simple to operate• Elimination of

sealing air fans • Elimination of

manual dampers• Elimination of

internal piping• Elimination of air-beams• Simple and easy controls• Less fans

Simple to maintain• Elimination of

moving grates• Elimination of side seals• Elimination of clinker

fall-through• Elimination of spillage valves• No undergrate

conveying system• Easy replacement

of wear parts

MAXIMUM AVAILABILITY

Easily replaceable wear parts

• reduced amount of cooling air and con-sequently lower air quantity for dedusting

• reduced number of cooling air fans• separated mechanisms for conveying of

clinker and cooling of clinker

Easy maintenanceThe number of wear parts has been min-imised through the simple design of:

• Cross-bars• Retainer brackets• Sealing profiles.

Moreover, these parts are designed to lasttwo “campaigns” or more.

Grate plates are no longer consideredwear parts.

All wear parts in the cooler are easilyreplaced in less than four days.

An SF Cross-Bar Cooler therefore requiresconsiderably less maintenance than anyother cooler available today.

Replaceable wear parts1 Sealing profile2 Cross-bar3 Bracket4 Wedge5 Pin

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Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice.

DENMARK F.L.Smidth A/SVigerslev Allé 77DK-2500 ValbyCopenhagenTel: +45 36 18 10 00Fax: +45 36 30 18 20E-mail: info@flsmidth.com

INDIAFuller India LimitedCapital Towers180, Kodambakkam High RoadNungambakkamChennai 600 034IndiaTel: +91 44-827-6030/8228623Fax: +91 44-827-9393E-mail: fil@fullerindia.co.in

USAF.L.Smidth Inc.2040 Avenue CBethlehem, PA 18017-2188Tel: +1 610-264-6011Tel: +1 800-523-9482Fax: +1 610-264-6170E-mail: info@flsmidth.com

www.flsmidth.com

Up-to-date addresses of worldwidesubsidiaries and sales offices are available from our website

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Reduced installation time and cost are achieved by the arrival of a preassembled module supplied from F.L.Smidth manufacturing shop.

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