Coolax Grate Cooler

The COOLAX high efficiency grate cooler
has greatly improved heat recuperation com-
pared with traditional coolers.
The efficiency of a grate cooler may be
characterised in terms of cooler loss, this
being the amount of clinker heat not recircu-
lated to the pyroprocess. Traditional cool-
ers have a loss of about 140 kcal/kg clinker.
The COOLAX has a loss of only 95-100
kcal/kg clinker.
In the heat recuperation zone (CFG zone)
the cooling air is supplied direct to
the grate plates through a system of ducts
and hollow beams instead of via an undergrate
compartment as in conventional coolers. Only
a small portion of the air enters the clinker
bed from the undergrate compartment This is
the sealing air.
The CFG zone is divided into sectors sup-
plied with cooling air from separate fans. The
sectors are subdivided into smaller segments
each with their own adjustable damper in the
air supply system.
After the CFG zone comes the after-cooling
zone with the Reduced Fall Through (RFT)
grate. Here cooling air is supplied from
undergrate compartments, as in conventional
coolers, but the grate plates are identical to the
ones in the CFG zone. The CFG system may
in special cases be used throughout the entire
cooler.
The movable grate rows start at the cooler
inlet, which prevents build up and reduces
snowman tendencies. Heat recuperation is also
improved this way.

The drive
RFT zone
CFG zone The first grate is driven by a centrally posi-
tioned cylinder and the following grates by
cylinders placed on either side of the cooler.
The hydraulic drives consist of axial piston
181 (C) pumps with electro-hydraulic servo-adjustment
of the oil flow to the cylinders which have
115 (B) built-in linear transducers. The system is con-
6 (D) 80 (E) trolled by a PLC.The pump units have built-in
397 (A) “swash” plates to regulate the oil flow and its
direction.
This ensures very smooth operation of the
moveable grate rows and perfect grate control.
The system is very reliable and maintenance
costs are low.
If preferred, a conventional mechanical drive
15 (F) can be supplied instead.

2.35 kg 32oC
(G)
A. Clinker heat including dust D. Radiation losses
B. Secondary air to kiln E. Excess air
C. Tertiary air to calciner F. Remaining clinker heat
G. Cooling air per kg clinker
Heat Values in Kcal/kg clinker
The heat balance shows a high recuperation of clinker heat resulting in effective cooling of the clinker and
substantial fuel savings due to the high secondary air temperature.

Grate plates
The pressure drop across the CFG grate plate
is higher than in traditional grate plates. This
ensures perfect air distribution through the
clinker bed and greatly improved heat recu-
peration.
In the CFG zone the cooling air is in full
contact with the inner surface of the grate
plates which are thereby constantly cooled.
The thermal load on the plates is therefore
low.
The plates are designed to prevent dust from
falling through. Each pair of slots is shaped
like an inverted T section. The principle is
that air will always travel outwards through
the slots while any dust entering the slots dur-
ing a stoppage will be trapped in the labyrinth
instead of falling through into the hollow girder
below.
A small amount of clinker dust will inevitably
fall through the slots when the kiln and cooler
are shut down. The dust is automatically
CFG grate plate with three double rows of air slots for controlled air flow.
cleared by the air flow at the next start-up.
Flexible connections
The air distribution system consisting of The high-efficiency COOLAX features
ducts and hollow beams incorporates
specially designed and highly reliable
! Fuel savings of 30-40 kcal/kg clinker
flexible connections between the fixed air ! 30% less cooling air and 40% less air to be dedusted
ducts and the moving grate rows.
! low overall power consumption
Intermediate roller crusher ! effective and consistent cooling of clinker
If the clinker is to be cooled to a very low
temperature a special type of roller ! more stable high capacity kiln and cooler performance due to
crusher may be fitted between the grate less dust circulation and no blowing through of cooling air
sections. The crusher reduces the size of
! low maintenance costs due to minimum wear on grate plates
the clinker and lumps of coating to attain
faster and more effective cooling. and movable parts
Also retrofit
! less red river tendency due to the Controlled Flow Grate
The COOLAX-CFG system is also well system
suited for upgrading existing grate coolers. ! less snowman tendency
In addition to the energy savings and
improved operational performance a ! less falling through of clinker
retrofit also allows increasing the through- ! small overall dimensions due to high specific grate load (up to
put within the overall dimensions of the
60 t/m2 per 24 hours).
existing cooler casing.
The COOLAX grate cooler is
available in three main versions :

SIZE SELECTION KEY LOAD ON GRATES ( T/M2 X 24H)

EFFECTIVE GRATE AREA (M2)

1. Flat bottom section with drag chains.

The size of cooler requird for a certain production capacity and specific
grate load can be read from the above diagram and below dimension
table. The example shows the selection of size 1490 for capacity 5,500 t/
24h and grate load 47 t/m2 x 24h
2. Bottom section with hoppers and sluices for external dust conveyor.
The permissible specific grate load depends on the required
clinker temperature after the grate and will normally be
within the range of 40 to 60 t/m2 x 24h.

3. Flat bottom section with roller crusher ahead of the last grate.

The main dimensions of the different types and sizes of

COOLAX grate coolers appear fromt he above table and the
sketches 1,2 and 3.
Data in this brohure is only intended for preliminary project Planning. Manufacturer reserves the right to modify equipment details and/or specifications without notice.

DENMARK: F. L.Smidth & Co. A/S. Vigerslev Allé 77. DK-2500 Valby Copenhagen.
USA: FULLER COMPANY, 2040 Avenue C, Bethlehem, Pennsylvania. 18017-2188.
F. L.SMIDTH & FULLER SUBSIDIARIES: AUSTRALIA: FULLER -
F. L.SMIDTH (PACIFIC) PTY. LTD. Level 4.156 Pacific Highway, Greenwich, N.S.W.
2065. BRAZIL: F. L.SMIDTH, COMÉRCIO E INDÚSTRIA LTDA. Rua Nebraska.
443. Brooklin Paulista-CEP 04560. Caixa Postal 3506,01051 São Paulo-SP.
CANADA: FULLER- F. L.SMIDTH CANADA LIMITED, lO.Thornmount Drive.
Scarborough, Ontario MIB 3J4. FULLER -FL.SMIDTHCANADALIMITED.3300
Cavendish Boulevard. Montreal. Quebec H4B 2M8. CHILE: FULLER-TRAYLOR, INC.,
Napoleon 3200. Of. 304. Las Condes, Santiago. FEDERAL REPUBLIC OF
GERMANY: F. L.SMIDTH - FULLER GMBH, Rheinstern Haus, Emanuel
Leutze Strasse 17,4000 Düsseldorf 11. FRANCE: F. L.SMIDTH- FULLER S.A.. 2/
4 rueVincentvan Gogh. 93364 Neuilly-Plaisance Cédex. ITALY: F.L.SMIDTH&C.
ITALIANA S.r.L.,Via Aterno. 26,1-66020 S. Giovanni Teatino (CH). JAPAN: FLS
Japan Ltd.,Togeki Building, 1-l.Tsukiji 4- chome, Chuo-ku, Tokyo 104. Postal address:
Kyobashi P.O. Box 78,Tokyo 104-91. MEXICO: F. L.SMIDTH-FULLER MEXICO,
S.A. DE C.V., Ave. Campos Eliseos 385,Torre “B”, Primer Piso, Chapultepec Polanco,
11560 Mexico City, D.F. P.R. CHINA: F. L.Smidth & Co. A/S. Beijing Representative
Office, Scite Tower. Room 1307,22 Jianguo Men Wai Dajie, Beijing 100004.
SOUTH KOREA: FULLER INTERNATIONAL, INC.. Independent Sales Office,
C.P.O. Box 2016, Hwa-Shin Building, 3rd Floor, 82 1-KA Bongrae-Dong, Choong-Ku,
Seoul. SPAIN: F. L.SMIDTH & CIA ESPANOLA, S.A., Carretera de La Coruna,
km. 17.8.28230 Las Rozas (Madrid). TURKEY: F. L.Smidth & Co. A/S.. Liaison Office,
c/o Trakmak.Traktörve Makine Ticaret Ltd. Sirketi, Ismet Inödü Cad., Mithat Pasa
Han. 92-94,80090 Giimussuyu, Istanbul. UNITED KINGDOM: F. L.SMIDTH -
FULLER LTD.. 17, Lansdowne Road, Croydon. CR9 2JT. LICENSEES/JOINT
VENTURES: INDIA: Larsen &Toubro Ltd.. Cement Machinery Division, Powai
Works, P. 0. Box 8901. Bombay 400072. FULLER - K.C.P. LTD., Ramakrishna
Building, No. 2, Victoria Crescent. Madras 600105. FULLER - K.C.P. LTD., 220, Arun
Chambers,}. Dadaji Road.Tardeo, Bombay 400 034. FULLER - K.C.P. LTD., 10-E,
Annapurna Apartments, 68. Ballygunge Circular Road, Calcutta 700 019.
FULLER- K.C.P. LTD., 1009. Tolstoy House. 15 Tolstoy Marg., New Delhi 110001.
SOUTH AFRICA: FULLER- F. L.SMIDTH (PTY) LTD., 363 Rivonia Boulevard.
Rivonia, P. 0. Box 1537, Rivonia 2128.