ABC cooler inlet

A new standard for

cooler operation
Key benefits
- No snowmen
- Increased availability
- Reduced wear on cooler parts
- Improved heat recuperation
- Fuel savings
- Better operational control

Cooler challenges
Use of lower-grade alternative fuels
in the cement industry is increasing.
Because these fuels vary in quality and
chemical composition, clinker granulometry and conveyance characteristics may differ. Unstable coating in the
kiln burning zone may fall down, and
processing difficulties may cause sticky
clinker. Both problems may cause
so-called snowmen and dead-zones in
the cooler inlet.
The ABC inlet solution
The FLSmidth ABC inlet combines
the advantages of a stationary inlet
section good service life and good
cooling-air distribution with the
advantages of a clinker conveyance
system, uniform clinker distribution
and effective elimination of snowmen.
This protects mechanical parts in the
cooler and eliminates undesired kiln
stops.

The blast zones enable you to

fully control how much, and
where to blast.

Cooling and blasting

cally decreased from 11 stops in the

last half of 2011 to no stops at all as
of November 2012 after conversion
to the latest Cross-Bar cooler layout,
which includes an ABC inlet.
Flexible control
Flexible control of the blasting zone
and the frequency and intensity of
blasts helps to optimise clinker flow
and distribution. The Mechanical
Flow Regulator (MFR) also improves
cooling efficiency. This flexible control
concept makes it possible to regulate
and optimise both the clinker bed
across the inlet and the conveying
speed. Better control of clinker flow
means fast, even cooling and better
heat recuperation.
Production savings
With improved heat recuperation from
your ABC Inlet, it will be possible to
decrease firing in the kiln or preheater,
saving expensive fuel.

No snowmen
Cement plants that experience snowmen in the cooling process spend a
great deal of time monitoring and
removing them usually manually,
which requires a kiln stop. At the
Rohoznik cement plant in Slovakia,
for example, kiln downtime dramati-

Controlled blast

One-shot Megablast on demand

ABC Inlet design

Frame
The fixed inlet consists of a steel support
frame which supports the air distribution
grates. Both the smooth grate line and
the built-in, forward-facing air slots
greatly enhance the clinker flow during
normal cooling operation.
Mechanical Flow Regulator (MFR)
The fixed ABC inlet section is aerated
with a well-proven system. The pressurised below-grate compartment
supplies cooling air to the clinker layer
via the MFR system. The MFR valves
maintain a constant flow of air through
each grate plate and automatically
compensate for the varying resistance of
the clinker bed by actively introducing a
pressure drop where needed hence no
need for the traditional air beams.
FLSmidth ABC cooler inlet

In-grate blast system

and cooling air
The MFR system maintains a supply of
cooling air to the inlet section, irrespective of the clinker bed and porosity. This
consistent cooling process is boosted by
a shock blaster system, which releases
compressed air directly through the
grates and into the clinker bed, using
the same air distribution system as the
normal cooling air. Sharing the same

Key design features

Tailor-made for your
cooler
Cast blast-grate plate
Proven MFR Technology
Flexible air blasting
in zones

distribution system ensures complete

area coverage for cooling and blast air.
The additional space requirement for
two different distribution systems is no
longer an issue.
Controlled blast
The blasting area is divided into 38
zones, depending on the size of the
inlet. Within each zone, blasting
frequency and intensity can be regulated
according to various schecules. Predefined programmes controlled from
the Central Control Room combine
zones, frequency and intensity in a set
pattern.

Project Centre Denmark

FLSmidth A/S
Vigerslev All 77
DK-2500 Valby
Copenhagen
Tel: +45 3618 1000
Fax: +45 3630 1820
E-mail: info@flsmidth.com

Project Centre USA

FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188
Tel: +1 610-264-6011
Fax: +1 610-264-6170
E-mail: info-us@flsmidth.com

Project Centre India

FLSmidth Private Limited
FLSmidth House
34, Egatoor, Kelambakkam
(Rajiv Gandhi Salai, Chennai)
Tamil Nadu 603 103
Tel: +91-44-4748 1000
Fax: +91-44-2747 0301
E-mail: indiainfo@flsmidth.com

www.flsmidth.com

C 08-13 400-27-ENG V2

Copyright 2013 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth, Cross-bar and ABC are (registered) trademarks of FLSmidth A/S. 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.