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ABC Air Blast Controlled cooler inlet

Total elimination of snowmen Innovative in-grate air blast system with

non-return flaps
Flexible control of blasting area, blasting

frequency and blasting intensity

ABC cooler inlet eliminates snowmen

Eliminates snowmen Prevents dead zones Ensures uniform clinker distribution Introduces flexible control of air blasting Based on well-proven Mechanical Flow Regulator (MFR) system Suitable for both new coolers and for retrofitting The cement industry is using lower-grade fuels and substituting an increasing amount of alternative waste products for traditional fuels and raw materials. Alternative materials, however, vary in terms of availability and chemical composition. As a result, clinker granulometry and conveyance characteristics may differ, and coating in the kiln burning zone may become unstable. Lumps of coating that subsequently enter the cooler and/or sticky clinker cause agglomerations, the so-called snowmen. Both snowmen and dead zones in the cooler inlet are therefore difficult to control and represent a growing problem. grate line with small steps and low friction. Both the smooth grate line and the built-in forward facing air slots greatly enhance the clinker flow during normal cooling operation. The improved clinker conveyance lowers the tendency to build up a stationary clinker layer and increases the tendency of uniform clinker movement and distribution, keeping the same velocity in all layers, which minimises snowman formations and dead zones and creates an optimum basis for heat recuperation. Despite the more uniform clinker conveyance concept snowmen may develop, and the unique in-grate blast system effectively removes them. As a result of the uniform conveying system and the effective in-grate blast system it is possible to design the geometry of the ABC Inlet for a thick (yet moving) clinker layer in the impact zone. This provides effective protection against the physical impact of the clinker falling from the kiln. Any increased wear caused by the uniform clinker conveyance is counteracted by the use of wear resistant materials and the thickness of the grates.

ABC inlet
The FLSmidth ABC cooler 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. The fixed inlet consists of a steel support frame which carries the air distribution grates. Each grate is divided into three levels, creating a smooth inlet

Blast air

Cooling air

The new inlet grates are reinforced in terms of material thickness and design and high temperature alloy is used in the actual impact zone

Mode 1: The air comes from the centrifugal fan up through the mechanical flow regulator and out through the grate, and access is blocked to the air blast duct.

Mode 2: The compressed air flap changes position so that it shuts off the cooling air duct. This ensures full utilisation and full impact of the blast air on the clinker bed.

Cooling and blasting

Cooling and blasting

One-shot Megablast on demand



The new ABC Inlet eliminates any downtime caused by snowmen, and it greatly reduces the manual and dangerous work of removing them. Combined with the uniform clinker flow which optimises heat recuperation, the reduced downtime and manual work mean a very short pay-back period for the ABC inlet. The ABC cooler inlet is suitable both for new coolers and for retrofitting different makes of existing coolers.

In-grate blast system and non-return flap

Most of the time, the well proven MFR system accurately maintains a consistent supply of cooling air to the inlet section, irrespective of the clinker layer and porosity. This consistent cooling process is supplemented by a shock blaster system of compressed air that is released directly to the grates and the clinker bed, using the same air distribution system (nozzles) as the normal cooling air. This novel concept of sharing the same distribution system ensures complete area coverage for both flows of cooling air, whilst avoiding the additional

space requirements of having two different distribution systems. In this way, the in-grate blast system precisely and effectively targets any snowman and dead zone, and the full area coverage of the cooling air optimises heat recuperation. The effect of the in-grate air blast on the clinker bed is due to stronger intermittent fluidisation of the area and high horizontal air velocity, effectively removing any snowmen and promoting the distribution and flow of clinker. A patented non-return flap ensures full utilisation of the blast air. When activated the flap shuts off the cooling air duct, and high pressure immediately builds up inside the grate (mode 2).

After the compressed air pulse, the pressure of the centrifugal fan immediately returns the flap to its original position. It then blocks the emptied air blaster duct and the clinker bed returns to its normal state (mode 1). By then, the clinker will have moved forward and to the sides (distribution). The improved flow of the clinker across the inlet prevents dead zones, agglomerations, and buildups/snowmen in the cooler.

Flexible control of blasting

The complete blasting area is divided into a relevant number of zones. Within each zone, blasting frequency and intensity can be controlled individually. A number of pre-set and customised

An example of a zone layout where the release of the in-grate blast system is operated individually in terms of impact and frequency allowing full flexibility to address certain areas with optimum intensity.

blasting programmes that vary in intensity and frequency may be selected from the central control room. If the clinker tends to form dead zones or snowmen in certain sections of the inlet, these problems are addressed by increasing the air blast intensity and frequency in the relevant sections. By only targeting the problem areas, the in-grate blast air is used most effectively. This also reduces unwanted dust circulation. The flexible control concept makes it possible to regulate and optimise both the clinker bed across the inlet and the conveying speed. Better control of the clinker flow means optimisation in terms of fast and even cooling and better heat recuperation.

During normal operation, the mechanical flow regulators control the supply of air.

Short periods of intermittent stronger fluidisation of the area and the impact of the high horizontal air velocity together result in effective removal of any snowman formations.

Mechanical Flow Regulator (MFR)

The fixed ABC inlet section is aerated according to the well-proven system used in all FLSmidth Cross-Bar coolers. The pressurised below-grate compartment supplies cooling air to the clinker layer via the Mechanical Flow Regulator (MFR) valves. There are no air-beams. 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.

Back to normal operation with no snowmen and a uniform clinker bed

Our 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 any time. Please contact us for specific information or data that may relate to your interests.

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

FLSmidth Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Tel: +1 610-264-6011 Tel: +1 800-523-9482 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com

FLSmidth Private Limited FLSmidth House 34, Egatoor, Kelambakkam (Old Mahabalipuram Road - Chennai) Tamil Nadu 603 103 Tel: +91-44-4748 1000 Fax:+91-44-2747 0301 E-mail: indiainfo@flsmidth.com 04-07-000 FLSmidth

FLSmidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 36 18 10 00 Fax: +45 36 30 18 20 E-mail: info@flsmidth.com