Cross-Bar® Cooler

Maple Leaf 3, Pakistan

Process Instruction

Date: 08-Feb-2018
Created by: JTHO

Doc. No.: 70039031-1.0

Cross-Bar® Cooler
Process Instruction: 70039031-1.0

List of contents
1.0 General notes ..................................................................................... 3
2.0 Construction and operating principle ....................................................... 4
3.0 Safety and protection ........................................................................... 8
4.0 Preparations before operation ................................................................ 9
5.0 Operation ......................................................................................... 11
6.0 Operational controls ........................................................................... 17
7.0 Operating parameters and alarm limits ................................................. 19

NOTE!
The present instruction manual is concerned with the situations which, according
to the experience of FLSmidth, are the most likely to occur. An exhaustive
enumeration of all conceivable situations, which may occur during manufacture,
installation, operation and maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen
in the instruction manual, and which the operator is/or feels unable to handle, it
is recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

Separate instruction manuals

The plant under review also comprises several other instruction manuals
containing detailed information about the single machines or arrangements.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

1.0 General notes

The primary objective of the present manual is to provide guidelines for start-up,
normal operation and stopping of the clinker cooler.
The directions, outlined in the manual, are basically of general character, since
many relevant factors relate to specific or local conditions. Therefore, a clear and
adequate description hereof cannot be provided in an instruction manual.
This manual is intended for introducing the operator to the Cross-Bar® clinker
cooler system. It should also help the operator when he has to make decisions in a
given operating situation.
In this manual it is presumed that the panel equipment has been installed and
tested and that the equipment is operational to its full extent.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

2.0 Construction and operating principle

2.1 Design specifications

Design specifications

Cross-Bar® Cooler type CB 18x58 iHRB

Grate area 174 m²

Operating rate 7300 t/d

Grate load 41.9 t/d/m²

Total fan design airflow 2.0 Nm³ air/kg clinker

Number of cooler fans 10

Cooler inclination 0°

Clinker outlet temperature 65 °C above ambient

The cooler nomenclature, in the table above, describes the number of grate plates
(width x length) that the cooler consists of and includes the inlet section.
2.2 Operating principle
The clinker leave the kiln at around 1450 °C and fall down onto the fixed inlet zone,
after which they are transported slowly down through the cooler. While being
transported through the cooler the clinker are constantly exposed to a cooling air
stream from below with the purpose of cooling down the clinker as well as
recuperating heat back to the kiln system.
The cooling air is provided by the fans installed for the cooler. When the cooling air
passes up through the clinker bed, it is heated by the clinker and for the first part
of the cooler the heated air is drawn back into the kiln system and used as
combustion air. Approximately 45 % of the total cooling air is returned back to the
kiln system and recuperates approximately 75 % of the clinker heat back to the kiln
system. The remaining air is extracted as excess air from the cooler.
The excess air extracted from the outlet end of the cooler and is dedusted in the
cooler excess air filter. The clinker dust from the cooler filter is transported to the
clinker conveyor.
At the outlet of the cooler a clinker crusher is installed for breaking large clinker
lumps.
2.3 Construction principle
The grate systems for the Cross-Bar® cooler is comprised of:
• Fixed inlet section
• Cross-Bar® sections
The air from the cooler fans is distributed throughout the cooler with each fan
supplying air to its own air compartment.
The following two figures gives examples of the Cross-Bar® cooler construction
principle. Drawings does not necessarily reflect actual installation.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

Figure 1: FLSmidth® Cross-Bar® cooler - overview example

Figure 2: Top view showing example of fixed inlet and first crossbar sections

Figure legend
1 Fixed inlet under-grate compartment.
2 First crossbar under-grate compartment.
3 Second crossbar under-grate compartment.
4 Grate rows in the cooler sides.
5 Second grate rows from cooler sides.
6 Minimum 600mm clinker bed height measured from top of grate plates.
7 Drive frames next to the cooler sides with reduced cylinder stroke length.
8 Several inspection hatches are installed in the casing walls for inspecting the clinker bed.
9 Thermocouples are installed in the grate line near the first crossbars.
10 Mechanical flow regulator

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

2.3.1 Fixed inlet

The inlet grate area is made up by cast grate plates. The grates are placed in a
sloped angle to promote clinker flow. The air flows out horizontal from the grates
through a number of aeration holes. The grates have smooth surfaces which
together with the forward facing air slots promotes the flow of clinker during
operation. Blast air is directed through the grates and is channeled out through the
grates horizontal air sloths.
Air blasters are also installed in the fixed inlet wall. There are a series of air blaster
channels (ABC). The selection of ABCs can be changed during operation, as also the
sequence of shooting can be changed during operation. One air blaster is installed
to blow kiln sealing dust back into the cooler.
A cast curb on each side of the fixed inlet is provided to achieve a better clinker
distribution on the grate area. (Cast curb = called a horse shoe, a specially formed
refractory side wall).
Some of the grates has thermocouples installed for measuring the grate plate
temperatures. These temperatures can be monitored from CCR in order to access
the process.
2.3.2 Cross bar sections
The cross bar section consists of the fixed grate plates with the cross bar transport
system located above the grates.
Below the grates the cooler is divided into a number of compartments, each being
supplied with air from their respective cooler fan attached.
2.3.3 Mechanical flow regulator (MFR)
Each grate plate for the cooler is equipped with an MFR (mechanical flow regulator).
The MFR limits the airflow through the grate by varying its pressure resistance.
The MFRs come in various capacity ranges, which make it possible to create an
airflow distribution pattern to suite a specific clinker granulometry. Therefore,
several sizes of MFRs can be found within the same section.
The MFR is described by two characteristics:
1. Maximum pressure drop compensation capability
2. Flow rate maintained within this pressure range
The MFRs are marked with 5 to 7 digit identifiers.
The first 4 to 6 digits show the flow of kg/m²/min and the last digit shows the
range of differential pressure of operation in kPa. The m² refers to the area of the
grate plate where the MFR belongs.
Examples:
• MFR type 40404, has a flow rate of 40 to 40 kg/m²/min with a differential
pressure of 4 kPa range of operation
• MFR type 1201204, has a flow rate of 120 to 120 kg/m²/min with a
differential pressure of 4 kPa range of operation
When the MFR is moving at approx. 10° - 45° angle the air through the grate is
according to the MFR nominal flow.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

If the installed MFR pattern is not suitable for the long-term production level or
characteristics of the clinker, the MFRs can be changed to match the actual needs.
The plant personnel should keep track of any changes performed.
2.3.4 Cross bar clinker transport
To provide for clinker transport through the cooler, the cooler has a number of
moving cross bars, which are moved using a system of hydraulic drives and
pistons.
2.4 Measurements and indications
2.4.1 Compartment pressure
The pressure in the compartments below the grates are measured. Pressures are
indicated locally and in the CCR.
2.4.2 Fans
All fans normally feature flow measurement, power consumption readings, airflow
adjustments can be with fan inlet damper adjustments or by fan speed control
depending on the installed fans.
2.4.3 Grate temperatures
Thermocouples are mounted in the following locations:
• Fixed inlet plates in compartment 1
• Cross-Bar® grate plates in compartment 2 or 3
There is remote indication to the control room of all grate temperatures.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

3.0 Safety and protection

3.1 Inspection and maintenance
Precautions and warnings while working in and around the clinker cooler
• Do not enter into the cooler when flame is lit in the kiln
• Certify cyclones and calciner are empty and free of material before entering
into the cooler
• Ensure any material build-ups on walls and ducting (excess air, hot air, kiln
hood, TAD) which can fall into the cooler are removed prior to entering in
the cooler
• Air blaster cannons must be empty and isolated such that air cannot flow
into the airtanks intentionally or unintentionally

Lock out and tag out the following equipment before working on the cooler
Kiln
• Kiln drive
• Kiln feed
• Fuel to kiln
• Primary air fan (kiln)
• Preheater ID fan
Cooler
• Air blaster cannons
• Cooler drives
• Cooler fans
• Clinker crusher
• Clinker transport

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

4.0 Preparations before operation

The personnel must be well informed about the control system, layout and
operating principle. This particularly applies to the knowledge of all interlocking
diagrams specifying protective, safety and operational interlocking.
4.1 Preparation
The following jobs must be completed prior to the start-up:

A • Inspect grates
o Ensure plates are not blocked so air may pass through as
intended
o Grates must be free from debris (steel, refractory, castable,
etc.)
• Measure cooler wall height reference points
o Height from the grate line to a number of wall reference
points are measured, enabling clinker layer height to be
visually determined during operation
• Check installed MFR's
o MFR’s should move freely
o MFR layout must be checked to match the design layout
• All doors to the cooler compartments and cooler must be closed

B No load testing is to be performed on all machinery associated with the

cooler department, both locally and from CCR.
• Manual operated valves are set to correct position for operation
• Cooler drives
o The hydraulic system no load test including start from the
local control cabinet
• Clinker crusher
• Cooler fans
o Confirm cooler fans airflow measurements between 60 and
100% of fan design at incremental step of 10%, using
piezometer value and the fan amps/kW consumption

C Test the control system

• Ensure all interlocking are active and functions as intended
o Safety, Protective, and Operational interlocks
o Alarm limits must have been set
• No interlock alarms must be present

4.1.1 Protection of grate plates

The entire fixed inlet and the Cross-Bar® grates line must be covered with a
protective layer of cold clinker nodules or alternatively limestone if clinker are not
available, preferably containing next to no dust. The clinker can be charged to the
fixed inlet of the cooler and distributed gradually by jogging the cooler drives (only
while fans are running). The cooler is ready for operation, when the clinker is
evenly distributed, over the whole grate and starts to leave the cooler.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

4.1.2 Drying of castables

If special requirements for the first-time drying-out of refractory castables have
been stipulated by the supplier of the Cross-Bar® cooler lining, ensure compliance
with such requirements during the start-up procedure.
4.2 Readiness for start-up
Having complied with the previous section, the electrical and the mechanical
departments must announce that the installation is ready for operation.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

5.0 Operation
5.1 General
The two prime objectives of the Cross-Bar® cooler are as follows:
• To cool the clinker
• To recuperate heat from the clinker back to the kiln system
In normal operation the objectives above are achieved by slowly over moving the
clinker through the clinker cooler over a period of approximately 25 minutes, while
aerating the clinker layer from below with a proportionate airflow of around
1.8 Nm³/kg clinker.
5.2 Starting up
To provide air for the kiln burner at the initial heating up, a few selected cooler fans
can be started up slowly according to the air demand of the kiln.
Gradually as the clinker begins to leave the kiln, the Cross-Bar® cooler must be put
into operation.
1) Start the clinker transport
2) Start the dust conveying system for the excess air handling equipment
3) Start clinker crusher
4) Start the cooler excess air fan
a) Adjust the negative pressure in the kiln hood to about 0.5 mbar and set the
PI(D)-regulator in automatic mode
5) Start all cooler fans not already operating
a) Maintain all compartment pressures above their minimum alarm setting (20
mbar for the fixed inlet and first two Cross-Bar® compartments and 15 mbar
for the rest)
6) To avoid a build-up of clinker on the grates
a) Cooler drive can be started stepwise with the increasing material flow from
the kiln
7) Gradually as the production increases
a) Cooling air is increased
8) Start the cooler drive
a) Continuous operation beginning with minimum stroke speed
b) The cooler drives must be in operation before the kiln drive can be started.
This interlock can be overruled during the heating-up period.

Note!
It is desirable to place the cooler excess air fan in automatic mode as early into the
preheat mode as possible. Once the excess air fan automatically controls the kiln
hood draft, it is easy to bring any remaining cooler fans on line.

5.2.1 Cooler fan airflows

For full production, the expected operating airflow rates are given at the end of this
document. The values can be used as a relative guidance when operating at lower
production levels. Use PI(D)-regulators for setting of all the airflow rates. This
means that the cooler will be controlled automatically right from the start.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

5.2.2 Initial operation

As the clinker layer builds, the compartments below the grates will begin to
pressurize. The cooling air to all the cooler compartments should be adjusted to
ensure adequate cooling of the clinker in order to reach the desired discharge
temperature.
To establish and maintain an adequate clinker bed depth the speed of the cooler
drives must be increased in proportion to the kiln output. It is suggested to keep
(manually) increasing the cooler drive speed, to attain a pressure of 60 to 80 mbar
under the first Cross-Bar® compartments as a preliminary target value. The clinker
bed is maintained at 600 to 660 mm.

Note!
Operate with min. 20 mbar on the inlet and the first two cross-bar compartments,
and min. 15 mbar on the remaining. This will protect grate plates from blocking and
ensure clinker is not forced backwards through the grate plate and into the under
grate compartments.

An optimization of the clinker bed depth will take place when the kiln performance
becomes more stable.
If the clinker tends to accumulate excessively on the fixed inlet, or if agglomeration
of clinker occurs, increase the air to the fixed inlet. If the problem persists the air
blasters can be programmed to shoot more frequently to facilitate movement of the
clinker.
5.3 Operation
5.3.1 Clinker layer
The clinker layer in the cooler is controlled by the speed of the cooler drive. This
speed is controlled by means of the ratio between two pressures:
1) The average pressure in the rectangular tower between the air distribution plate
and MFR in the first Cross-Bar® under-grate compartment (plate pressure), in a
ratio of 50 to 100 % (default 80 %)
2) The pressure of the fixed inlet under-grate compartment, in a ratio of 0 to 50 %
(default 20 %)
The combined fractions of the two pressures should always add up to 100 %.
The set-point for this controller will in automatic mode maintain the clinker bed
depth accordingly:
• Decreasing bed depth; the combined pressure will decrease, and the speed
will reduce
• Increasing bed depth; the combined pressure will increase, and the speed
will increase
In case the controller is in manual mode, for example in case of a flush from the
kiln, the cooler drive speed should be changed very slowly, i.e. 0.5 stroke/minute
at a time. It is normally recommended to try to maintain a normal drive speed and
do not overreact as long as the cooler fans can keep the airflow set-point. A rapid
change, especially if increasing the stroke speed, is likely to reduce the clinker layer
too much and expose the crossbars or even the cooler grate plates to excessive
temperatures, which can damage them.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

It is important to maintain a consistent clinker bed in the cooler. If the bed is too
low the retention time of the clinker in the cooler will be too short, and that will
affect the clinker temperature and heat recuperation. Also a low bed dept will
increase the risk of overheating the grates.
5.3.2 Cooler fans
Shortly after start-up of the cooler, the cooler fan airflow control should be placed
in automatic mode for maintaining sufficient airflow to the compartments below the
grates.
The set point of the airflow control must gradually be increased as the clinker bed
depth is reaching the desired level of typically 600 to 660 mm.
5.3.3 Visual inspections of under-grate area
Regular, periodic inspections of the under-grate area are made from the outside
through the view ports. Ensure the MFRs are operating freely, that there is no
clinker fall-through into the compartment, and that there is no leaking of hydraulic
oil from the hydraulic system.
During normal operation, also bolted connections in the under grate compartment
should be monitored. During start-up, frequent inspections are required.

Note!
Leaking of hydraulic oils in the under-grate compartments will lead to dust buildup
inside the grate plates and hereby reduce the airflow through the plates, and may
also stop the MFR's from moving freely. Stop the hydraulic leaks as soon as
possible to avoid loss of cooler operational performance.

5.3.4 Visual inspections of clinker layer.

Regular periodic inspections of the clinker layer should be made. Inspections of the
clinker layer can prevent poor operation with low clinker bed height that leads to
overheating the grates.
A cooler in stable operation has a uniform flow of clinker across the entire grate
area. The airflow through the clinker bed should be sufficient to keep the surface of
the clinker bed slightly percolating (small sized clinker are hovering above the
clinker surface) without any major blow-through.
5.3.5 Grate temperatures
Grate line temperatures are measured across the cooler width, around 3 meters
from the fixed inlet. Measurement is made just above the grates. Under certain
operational conditions the temperature may increase into the alarm region. In such
cases actions are automatically made from the sub control system to counter act
potential heat damage to the grates, by reducing the drive speed to the adjacent
cross bar lane where the high temperature has been measured.
Depending on the level of the temperature alarm for the grate temperature, the
applied action is to gradually reduce the transport efficiency (reduced stroke length)
for the drive. High alarm 3 will stop the drive until the temperature drops.
The operator must observe if the applied changes by the interlock are sufficient or
additional corrections are required, such as reducing the drive speed even further
to increase the clinker layer to help protect the grate line.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

5.3.6 Fixed inlet

The air to the fixed inlet ensures a fast quench of the clinker leaving the kiln. It is
essential to ensure that the airflow at the fixed inlet section is adequate, since this
airflow is a contributory factor for distribution of clinker across the whole cooler
area.
At low airflows the clinker will begin to agglomerate and stick to each other,
causing poor clinker distribution from inlet to the Cross-Bar® sections and hereby
poor cooler performance and risk of clinker build-ups ("snowmen" formation). At
high airflows the cooler recuperation will be reduced.
The fixed inlet should have just enough air so that the clinker does not agglomerate
during normal operation. Check and adjust the airflow to the fixed inlet while
observing the clinker layer (inspect from outside the cooler through viewports).
5.4 Trouble shooting guide
5.4.1 Low bed depth
The cooler drive speed is too high. Reduce the cooler drive speed and/or increase
the set-point pressure which controls the cooler drive speed.
Difference in clinker granulometry may lead to different pressure loss for same
layer depth and airflow.
5.4.2 MFR fully open
Not necessarily a problem. The airflow through the MFR's is less that the nominal
MFR capacity.
The normal case would be that at least a few of the MFR's in the chamber would
move just a little, depending on how close the applied air to the compartment is to
the MFR's total nominel capacity.
Verify that the desired airflow is being delivered to the air compartment by
checking the fan power, flow, pressure and piezometre set-point.
5.4.3 MFR fully closed
The airflow through the MFR's is same or larger than the MFR's nominal flow
capacity. It is not possible to get more air into the compartment, as the MFR's will
counter any such attempt, and the result would only be an increased power uptake
of the cooler fan.
Should more air be required to the compartment, the MFR's will have to be
modified or changed, to suit a required larger flow.
5.4.4 Clinker fall through
Check actual compartment pressures are above the min. of 15 - 20 mbar. If the
pressure is too low, pressure must be increased by increasing the fan airflow and/or
clinker bed debt.
If fall through is occurring and is persistent, the cooler must be stopped and
mechanically inspected for faults.
5.4.5 Caking or crusting of the clinker bed
The airflow, especially on the fixed inlet, should be increased to ensure proper
cooling of the clinker which should prevent clinker agglomerations.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

5.4.6 Poor material distribution on the fixed inlet

The distribution of clinker is dictated by the amount of inlet airflow, and the grate
speed. If clinker build-up formations occur in the fixed inlet area, increase air
blaster sequence time or shoot manually with air blaster in problem area.
5.4.7 Kiln flush
If the cooler grate line temperatures give alarm on high temperature during or just
after a kiln flush, reduce cooler drive speed and reduce the cooler airflow in order
to minimize fine dust fluidization on the cooler grates.
5.4.8 Dusty clinker
The clinker cooler can handle dusty clinker, if the airflow to the grates is not too
large. If high airflows are applied to the Cross-Bar® cooler sections the dust will be
entrained / fluidized and circulate between the kiln and cooler. Initial steps of
handling dusty clinker would be to lower the amount of air to the recuperation
zone, simply by reducing the cascade factor. If this does not prove to be sufficient
it could be beneficial to change the MFR regulators, preferably with size 4040X to
6060X out near the cooler sides if not already installed. The recup zone is normally
installed with size 8080x MFR's in the center and stepped down in the outer two
grates lanes by 6060X and 4040X near the wall.

5.5 Alarms

Low compartment pressure Indicates low airflow through the grates.

Cross-Bar® drive is stopped on interlock.

High grate temperature Indicates low bed thickness and/or fluidization of

fine clinker dust. The Cross-Bar® drive speed and
airflow is reduced on interlock.

Make visual inspections of operation to check the

clinker bed height and airflows. If dusty clinker is
causing fluidization then reduce the airflow to the
areas where the high temperatures are observed.

High excess air temperature Increase the cooling air to the cooler.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

5.6 Stop of cooler

The clinker cooler normal stop is related to the kiln system stop. The normal
process interlocks are as follows.

Kiln stop Cross-Bar® drive is stopped on interlock.

Kiln barring will give some clinker to the cooler. If

required to move these clinker (visual inspection),
then the cross bars (while the cooler is aerated) can
be moved slowly and carefully, so not to risk
lowering the clinker layer and potentially exposing
the grates to hot clinker.

Cross bars Cooler fan airflows are forced down by interlock to

pre-set default speeds (or damper positions), which
have been set individual for each fan (typically
around 40 to 60 %). Cooler air fans are set to
manual control.

Maintain sufficient air to the grates to keep grates

and the cross bars cool.

If the kiln stop lasts for more than a day, the cooling fans are stopped, when the
clinker inside the cooler has been cooled sufficiently to avoid heat damage to the
clinker cooler.

Note!
The cooler should not be emptied for material, unless this is necessary in order to
carry out repairs. For repair works, it is only necessary to empty out material in
local areas.
Maintain a normal layer of clinker in the cooler, until the kiln has been cooled off
completely, and inspection has been carried out in the kiln.
After eventual repairs in the kiln, and discharge of old lining or crust are finished
first then will it be practical to empty out the cooler.
Emptying of the cooler by means of the grate drives must be done with great care.
The clinker bed should be visually monitored during emptying out, and the grate
must be stopped, when the cross bars get visual. The remaining clinker must
hereafter be removed by other means than the cross bar drive.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

6.0 Operational controls

The various motors, machines, dampers and other equipment are operated and
controlled by the central control system. The typical process operating controls are
given in the following.
6.1 Control loops
The following control loops are foreseen, with the possibility for automatic or
manual control:

Control of By regulating
(typical PID reg.)

Kiln hood pressure Excess air fan speed

Clinker layer is indirectly controlled by; Speed of cooler drives

Grate pressures (ratio between fixed
inlet and Cross-Bar® grate section)

Cooler fan airflow Fan speed control (or damper if

installed)

6.1.1 Cooler fans

The cooler fans can operate in cascade mode. The cooler fans below the Cross-Bar®
sections are grouped into two zones.
• Recuperation zone
• Cooling zone
The cascade mode allows the operator to give a proportional factor input to the
zone (typical 0.6 to 1.1). The factor is multiplied with the default fan flows for the
group to give the set point flow for the cooler fans PID control. Default fan flows are
set initially as expected operating flows.
When operating with cascade mode on, the operator can increase the airflow simply
by setting the cascade ratio factors and the cooler fan airflows will be changed
proportionally.

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

6.2 Interlocks
For easy reference the below tables list the most common process interlocks for the
Cross-Bar® Cooler. For a full list of interlocks please refer to separate
documentation presenting the interlock diagrams for the clinker cooler.

Equipment Condition Action

High 1 alarm Reduced stroke length of adjacent drive

Grate plate temperature > 450 °C by 20-40 %
Cross-Bar® grates
High 2 alarm Adjacent cooler drive stopped after
> 600 °C pre-set delay (default 10 min)
(handled in sub control
system) High 3 alarm
Adjacent cooler drive stopped instantly
> 750 °C

Clinker crusher Stopped

Low 2 pressure
Cooler fan (any) Or
Stopped
Cooler drive is stopped
Stopped
Excess air fan
(5 min. delay)

Kiln drive Stopped

Excess air temperature High 2 alarm Excess air fan stopped

Kiln speed < 1.5

Fixed inlet shock blaster program is
Fixed inlet pressure < 45 mbar stopped (auto start if conditions are not
fulfilled)
Cooler drive Stopped

Stopped or
Preheater ID fan Cooler fan flows reduced to a default
forced down
speed setting/damper position (typical
around 60 %)
Excess air fan Stopped

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Cross-Bar® Cooler
Process Instruction: 70039031-1.0

7.0 Operating parameters and alarm limits

The following tables are a survey of the expected normal operating parameters and
the normal alarm limits. The operating parameters stated are for guidance only and
apply to the normal, stable operating situation. The operating limits stated are
meant as guidance for start-up. It will be possible to adjust many of them with
advantage later on in order to make them more suitable for the actual operation.
Consult with mechanical and electrical departments before changing alarm limits,
as some of the alarms are used to protect the machine.
See also mechanical installation manual as well as the flow diagram for codes and
instrumentation.

The following notes refer to the tables listed below

a To be fixed in accordance with the specifications in separate machine instruction

b To be fixed in accordance with the electrical documentation

c To be fixed empirically so the alarm is not activated under normal operating

conditions

x The normal value is either given in above text or has to be evaluated during
commissioning

+ Indication given according to range of instrument

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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 19 of 21
Cross-Bar® Cooler
Process Instruction: 70039031-1.0

Operating and alarm

limits

Expected value

High 3 Alram
High 1 alarm

High 2 alarm
Low 2 alam

Low 1 alam
Alarm
Kiln hood mbar -0.5 0

°C 1050

Grate temperatures °C x 100 150 300

Fixed inlet

Grate temperatures °C x 450 600 750

Cross-Bar® grates

Grate pressures mbar 60 / x

(clinker layer)

Cooler drive Amps. X a)

stroke/min x

bar x 160 250 280

Excess air fan rpm x

Amps. x

Excess air temperature °C 320 x x x x

Clinker crusher Amps. x

Cooler drive hydraulic bar x 160

pressure

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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 20 of 21
Cross-Bar® Cooler
Process Instruction: 70039031-1.0

7.1 Cooler fan airflows

The cooler fan airflows must be calculated according to the formula below:

1
= ⋅ ⋅ √dP
273.15 +

= 35.244 ⋅ ⋅ ⋅
where

Q Normalized flow in Nm³/min

K Constant calculated for each fan

D Diameter of the venturi (different for each fan) in meters

F Flow constant for the venturi (0.63 for standard FLS type)

Pbaro Barometric pressure of the plant in mmHg

Tambient Actual ambient temperature in °C

dP Differential pressure measured over the venturi in Pa

Cooler fans Speed Air flow Pressure

Description regulation Range Expected Low1 Range Expected Low2 Low1
Nm³/minNm³/minNm³/min mbar mbar mbar mbar

k11 : FN300 Yes 0 to 430 339 203 0 to 100 72.5 20 25

k12 : FN305 Yes 0 to 960 759 455 0 to 100 72.5 20 25
k21 : FN310 Yes 0 to 720 599 359 0 to 90 65 20 25

k31 : FN315 Yes 0 to 930 769 462 0 to 90 65 20 25

k41 : FN320 Yes 0 to 1030 852 511 0 to 80 60 20 25

k51 : FN325 Yes 0 to 1450 1198 719 0 to 80 60 20 25
k61 : FN330 Yes 0 to 1570 1296 778 0 to 70 55 15 20
k71 : FN335 Yes 0 to 1180 976 586 0 to 70 55 15 20
k81 : FN340 Yes 0 to 1370 1136 682 0 to 70 50 15 20
k91 : FN345 Yes 0 to 1490 1229 737 0 to 70 50 15 20

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may not be duplicated, disclosed or utilized without written consent from FLSmidth. 21 of 21