FLSmidth®

Cross-Bar® Cooler
The latest standard
in clinker cooling
technology

WE DISCOVER POTENTIAL
 Setting the standard in
clinker cooling technology
The FLSmidth® Cross-Bar® cooler represents the latest
evolution in clinker cooling technology. It is based on
proven and refined FLSmidth cooler technology. The result
is a cooler representing the highest standard in clinker
cooling technology at an attractive investment level.

Key benefits

No Snowman formation High reliability Low, easy, predictable

with ABC™ inlet and availability maintenance

Consistently high Energy-efficient Fast and simple

thermal efficiency installation

Highly flexible in upgrading Low civil, construction No fall through of clinker to

existing coolers and operating costs the undergrate compartment
The FLSmidth® Cross-Bar® Cooler

Making the best even better Six fundamental design features

Similar to our previous coolers, which revolutionised the way clinker Six fundamental design features play a key role in its
coolers are installed, operated and maintained, the FLSmidth superior performance:
Cross-Bar cooler features a stationary grate line with no undergrate ■■ Air Blast Controlled inlet

spillage or conveying system, separation of the conveying and cool- ■■ Self-adjusting mechanical flow regulators

ing systems, air distribution plates with mechanical flow regulators, ■■ Stationary, sealed grate line

and modular construction. In the FLSmidth Cross-Bar cooler, all bars ■■ 

Separate clinker conveying and cooling systems
are movable and reciprocate so as to optimise transport efficiency ■■ Horizontal design with optimised transport method

and enable horizontal installation. ■■ Modular concept

Quick and easy to install, the FLSmidth Cross-Bar cooler ensures The FLSmidth® ABC™ fixed inlet as standard prevents the formation
maximum availability with minimum maintenance. And with a com- of snowmen and gives an optimal start to the cooling process with a
pletely new size and structure of its modules, it makes for an ideal more uniform clinker layer.
new cooler or upgrade.
 The six fundamental
design features
Air Blast Controlled inlet Self-adjusting mechanical flow regulators
– No Snowman – Stable operation, fuel savings
MFR cooling process supplemented by an air blast released directly Each air distribution plate in the FLSmidth Cross-Bar cooler is
to the grates and the clinker bed. Eliminates snowmen and prevents equipped with a mechanical flow regulator (MFR) that regulates
dead zones where traditional blasters in back and side walls cannot the airflow via a self-adjusting orifice. This optimal principle of
reach. Ensures uniform clinker distribution. continuous airflow reg-ulation was invented by FLSmidth and
helps optimise heat recuperation and distribution of air throughout
the entire cooler. In turn, it enables fuel savings and few installed
cooling fans.

The MFR maintains a constant airflow through the air distribution

plate and clinker bed, irrespective of clinker bed height, particle
size distribution or temperature. Should the restriction of airflow
through one area of the clinker layer change, the MFR automatically
compensates for the variations in restriction and maintains the de-
sired airflow based on simple physics, without operator intervention.

Air through Air through

idle hole holes in
tongue

Air through
gaps

The proprietary mechanical flow regulator that each

air distribution plate is equipped with automatically
compensates for variations in restriction and maintains
the desired airflow without operator intervention.

High bed Low bed

resistance resistance

Low ∆P High ∆P
MFR MFR

Constant air flow irrespective of overgrate conditions

Stationary, sealed grate line Separate clinker conveying and cooling systems
– High reliability – Consistently high thermal efficiency
The FLSmidth Cross-Bar cooler has no movable grate plates. There Unlike other cooler designs, the FLSmidth Cross-Bar cooler sepa-
is no fall-through of clinker, and no undergrate clinker conveying rates the clinker conveying and air distribution systems. Reciprocat-
system or gap management of grates is required. A static layer of ing bars fitted above the stationary air distribution system effectively
clinker protects the air distribution plates against heat and wear, so convey, mix and shear the clinker while at the same time preparing
the plates are no longer a standard wear part. the clinker for efficient exposure to the cooling air.

A well proven and patented sealing design consisting of U- and A further benefit to this separation is that gradual wear of the bars
C-profiles around the drive plates forms a dust trap, preventing has no effect on cooler operation, and thermal efficiency stays high.
clinker from entering the undergrate compartment. No requirement
for undergrate spillage system.
Horizontal design with optimised transport method Modular concept
– Low civil costs, low wear rates – Fast, easy, cost-effective installation
The cooler’s new drive mechanism is designed to obtain optimal The FLSmidth Cross-Bar cooler is designed not only for completely
transport efficiency. Each lane of movable frames in the cooler is new coolers, but also as an upgrade for most existing coolers. To
operated by 1 to 3 hydraulic cylinders depending on the cooler meet these requirements, the cooler is constructed as a modular
size, and has an independent drive. While all bars move in a shuttle system with units of varying size.
motion, the movement of each lane can also be separately adjusted
to accommodate diverse clinker bed conditions. The standard units are preassembled in the workshop to ensure
high quality and swift, simple installation.
High clinker transport efficiency allows horizontal construction in
order to minimise installation height or maintain overgrate and kiln To form a whole cooler, a number of units are put together length-
hood velocities in cooler upgrades – leading to low cost of civil wise and widthwise, and the movable frames are connected along
work and reduced dust recirculation. the length of the cooler.

Step 1.

All lanes move forward

Step 2. Installation of FLSmidth Cross-Bar cooler inside existing

cooler housing

Every other lane moves backwards

Step 3.

The modular FLSmidth® Cross-Bar® cooler reduces installation

Remaining lanes move backwards time and costs. It is manufactured to a high quality standard and
ensures attractive equipment delivery times.
 Keeping you productive
today and tomorrow
Low, easy, predictable maintenance Attractive investment level
The FLSmidth Cross-Bar cooler has few wear parts, meaning easy As part of our efforts to provide you with the best investment
and economical maintenance. The bar and U-profile are held possible, we continuously develop our products, optimising them
simply in place by wedges and pins and easily accessible from from the standpoint of both technology and economy.
the overgrate area. During operation, a protective layer of clinker
is maintained between the air distribution plates and the movable The optimised design and manufacture of the FLSmidth Cross-Bar
bars, which ensures a long lifetime for the air distribution plates. cooler – with its horizontal construction, high thermal efficiency, low
Experience has shown that the maintenance of coolers is very power consumption and low maintenance – enables us to offer this
predictable and simple to perform. This makes for increased flexi- superior cooler with a low total cost of ownership.
bility of maintenance planning and prevents critical path situations
during a typical kiln overhaul. When maintenance is required, it will
normally only take a limited number of shifts to perform.

SIMPLE TO OPERATE SIMPLE TO MAINTAIN

■■ 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
Project Centre Denmark
FLSmidth A/S
Vigerslev Allé 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

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C 06-17 400-5-ENG

Copyright © 2017 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.