Pfc_the Great Cooler

The Source of Innovation

From Walking-Floor /1938 to PYROFLOOR® /2005 PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Walking-Floor: From 1938 …

© by KHD Humboldt Wedag AG

… to 2005

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

•

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

New Conveying Concept

Walking Floor Motion Pattern

Motion pattern of the aeration floor:

Forward push: all together now!

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Backward slide: no neighbors please!

Walking Floor Transport Simulation

Discrete Elements Model Simulation: Particle interaction: size weight friction....

⇒ No relative movement between floor and clinker – no wear! ⇒ High transport efficiency

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Colors: Yellow: stationary Green: slow backward Blue: backward (same speed like floor) Red: forward

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Walking Floor Conveying

PYROFLOOR® - The Great Cooler

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

• •

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

– highest heat transfer – low blow-through tendency – low red river tendency

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Aeration Cassette

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Aeration Cassette

Aeration Cassette

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

passive clinker layer

Streamline Simulations PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Aeration Cassette

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Aeration Cassette

•

without cast material

•

temperature strength up to 450 °C autogenous protection against wear / temperature

•

660 600

PYROFLOOR® - The Great Cooler

•

active cooling surface app. 80%

•

no longer wear part!

•

still they can be exchanged easily

© by KHD Humboldt Wedag AG

Aeration Cassette

•

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Flow Regulator

Flow Regulator Flow-Regulator: Characteristics 7000

450 400 plate position

6500

plate diameter 190mm spring 464N/m original 15mm pre-load

6000 5500 5000

300

4500 4000

250

3500 200

3000

working range

volumeflow w/o Flow-Regulator

150

2500

volumeflow [m^3/h]

2000

volumeflow with Flow-Regulator

100

1500 1000

50 undergrate pressure

500

0 0

50

100

150

200

250

300

seconds

PYROFLOOR® - The Great Cooler

350

0 400 © by KHD Humboldt Wedag AG

pressure [mbar], position [mm]

350

2000m³/h

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

New Aeration Concept: Aeration Cassette + Flow Regulator

PYROFLOOR® - The Great Cooler

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

•

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Static Inlet With Sealing:

Static Inlet 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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Grate:

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Static Inlet Seal

Static Inlet Seal Module

•

Spring force and gravity force loaded

•

Hardfacing with composite carbide with a temperature strength up to 550°C

•

No leakage

•

No riddlings

•

Self-aligning

•

Self-adjusting

•

All sealings identical units

•

Mounted from above and

segments

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

can be changed in

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Static Inlet Seal

PYROFLOOR® - The Great Cooler

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

• • • • • •

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Lateral Sealing Between The Lanes:

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Lateral Seal

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Lateral Seal

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Lateral Seal

PYROFLOOR® - The Great Cooler

Lateral Sealing Between The Lanes:

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

• 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

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Set-Up:

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Set-Up

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Set-Up

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Set-Up

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Modular Set-Up

PYROFLOOR® - The Great Cooler

Modular Set-Up: high quality prefabricated parts short installation times all grate dimensions available composed from only a few basic components

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

• • • •

PYROFLOOR® - The Great Cooler

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Hydraulic Drive:

Hydraulic Drive

backward stroke

hydraulic cylinder

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

forward stroke

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Hydraulic Drive

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

Hydraulic Drive

PYROFLOOR® - The Great Cooler

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

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

• • • •

Roller Bearing Combined Roller Bearing: •

long life >100.000h

•

lifetime lubricated

•

standard Part

•

compact design

•

radial and axial roller bearings

axial roller PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

radial roller

PYROFLOOR® - The Great Cooler 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® - The Great Cooler

© by KHD Humboldt Wedag AG

• • • •

– Your Future

PYROFLOOR® - The Great Cooler

© by KHD Humboldt Wedag AG

® PYROFLOOR