PFC - The Great Cooler

The Source of Innovation
PYROFLOOR - The Great Cooler

From Walking-Floor /1938 to PYROFLOOR /2005
by KHD Humboldt Wedag AG
Walking-Floor: From 1938
to 2005
2002: Vision of a New Clinker Cooler
PYROFLOOR : Requirements and Best Solutions

low maintenance costs:
R no more plates to be changed R minimization of wear part mass S no more cast parts plates made of welded steel standard components S easy access to remaining wear parts from above the grate
lowest possible wear:

R no conveying elements within the clinker layer R no pushing surfaces perpendicular to the direction of clinker movement S walking floor principle S cold clinker cushion for autogenous wear protection
optimal aeration highest efficiency:

R small aeration sections to be aerated individually R prevention of straying air S flow-Regulators (for moving systems) S contact sealings instead of labyrinth sealings
low Installation costs:

R low building height S no hoppers and spillage handling equipment S no fall-through-design
New Conveying Concept
Walking Floor Motion Pattern
Motion pattern of the aeration floor:
Forward push: all together now!

Backward slide: no neighbors please!
Walking Floor Transport Simulation
Discrete Elements Model Simulation:

Particle interaction: size weight friction.... Colors: Yellow: stationary Green: slow backward Blue: backward (same speed like floor) Red: forward No relative movement between floor and clinker no wear! High transport efficiency
Walking Floor Conveying
New Conveying Concept:

efficient conveying no relative movement between clinker and metallic surface no conveying elements within the clinker layer lowest possible wear clinker distribution
New Aeration Concept
New Aeration Concept: Controlled Aeration At Any Spot

Distribution of cooling air
clinker layer forms a 3Denergy field on the grate
bed height temperature
best condition: local supply of cooling air has to match the energy level at any spot of the grate
highest heat transfer low blow-through tendency low red river tendency
Aeration Cassette
Aeration Cassette
Aeration Cassette
passive clinker layer
Aeration Cassette
Streamline Simulations
Aeration Cassette
Aeration Cassette
without cast material temperature strength up to 450 C autogenous protection against wear / temperature active cooling surface app. 80% no longer wear part! still they can be exchanged easily
660 600
Flow Regulator
acts like direct aeration on the whole grate without the usual ductwork and pressure loss reacts on changes within the clinker layer loading by itself requires no automation requires no special supervision during operation unique patented design allows operation in movable systems prevents blow-throughs high heat transfer
Flow Regulator
Flow-Regulator: Characteristics
450 400 350 pressure [mbar], position [mm] 300 250 200 150 100 50
undergrate pressure plate position
7000
2000m/h
plate diameter 190mm spring 464N/m original 15mm pre-load
6500 6000 5500 5000 4500 4000 3500 volumeflow [m^3/h]
working range
3000
volumeflow w/o Flow-Regulator volumeflow with Flow-Regulator
2500 2000 1500 1000 500 0 400
0 0 50 100 150 200 seconds 250 300 350
New Aeration Concept: Aeration Cassette + Flow Regulator
New Aeration Concept:

many small aeration sections consisting of: aeration cassette (area < 0,4 m2) flow regulator local supply of cooling air matches demand bed height bed temperature supply of cooling air remains constant irrespective of bed disturbances no hot-spots, no fountaining best possible conditions for: high heat transfer troublefree operation
Static Inlet With Sealing:
Static Inlet Grate

Modular Grate: without cast material grate cover elements are 660 mm long and 600 mm width 3 elements long, for larger coolers 4. The grate cover elements are installed from above shock blowers installed in sidewalls and on the top of the grate
Static Inlet Seal
Static Inlet Seal Module
Spring force and gravity force loaded Hardfacing with composite carbide with a temperature strength up to 550C No leakage No riddlings Self-aligning Self-adjusting All sealings identical units Mounted from above and can be changed in
segments
Static Inlet Seal
Static Grate Inlet Sealing:

contact type with spring support hardfacing resistant up to 550 C no leakage, no riddlings self-aligning, self-adjusting all parts standardized and identical can be mounted from above the grate
Lateral Sealing Between The Lanes:
Lateral Seal
Lateral Seal
Lateral Seal
Lateral Sealing Between The Lanes:

contact section with sealing rope labyrinth section with hardfacing resistant up to 550 C autogenous pocket as back-up no leakage, no riddlings self-aligning, self-adjusting all parts standardized and identical can be mounted from above the grate
Modular Set-Up:
Modular Set-Up
Modular Set-Up
Modular Set-Up
Modular Set-Up
Modular Set-Up:
high quality prefabricated parts short installation times all grate dimensions available composed from only a few basic components
Hydraulic Drive:
Hydraulic Drive
backward stroke
forward stroke
hydraulic cylinder
Hydraulic Drive
Hydraulic Drive
Hydraulic Drive:
long stroke up to 350 mm standard parts lanes only pull, never push each lane driven individually: speed, strokelength and pause time controlled by intelligent controller
Roller Bearing
Combined Roller Bearing: long life >100.000h lifetime lubricated standard Part compact design radial and axial roller bearings
radial roller
axial roller

PYROFLOOR offers unrivaled advantages:
high heat recuperation: just the right amount of cooling air to any spot of the grate self-regulating aeration sudden changes within the clinker layer will be compensated automatically no more fountains optimum aeration on the whole grate wear if any will not influence aeration and heat transfer low wear: no more perpendicular pushing surfaces that would be subject to wear no more relative movement between clinker granules and metal parts no cast wear parts easy maintenance: no maintenance during the production year no exchange of spare and wear parts for at least two years only sealing related parts to be changed within years
PYROFLOOR
Your Future

PFC - The Great Cooler

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PFC - The Great Cooler

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The Source of Innovation

PYROFLOOR - The Great Cooler

Walking-Floor: From 1938

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

2002: Vision of a New Clinker Cooler

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR : Requirements and Best Solutions

lowest possible wear:

optimal aeration highest efficiency:

low Installation costs:

R low building height S no hoppers and spillage handling equipment S no fall-through-design

PYROFLOOR - The Great Cooler

PYROFLOOR - The Great Cooler

New Conveying Concept

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

Walking Floor Motion Pattern

Motion pattern of the aeration floor:

Forward push: all together now!

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

Walking Floor Transport Simulation

Discrete Elements Model Simulation:

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

Walking Floor Conveying

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

New Conveying Concept:

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

New Aeration Concept

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

New Aeration Concept: Controlled Aeration At Any Spot

PYROFLOOR - The Great Cooler

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

passive clinker layer

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

PYROFLOOR - The Great Cooler

6500 6000 5500 5000 4500 4000 3500 volumeflow [m^3/h]

2500 2000 1500 1000 500 0 400

0 0 50 100 150 200 seconds 250 300 350

PYROFLOOR - The Great Cooler

by KHD Humboldt Wedag AG

New Aeration Concept: Aeration Cassette + Flow Regulator

PYROFLOOR - The Great Cooler