certain size and shape, so that the availa- characteristics of the flow regulator

ble cross-section for the inflowing air can be designed.

changes with the plate position. As
a reaction to changing pressure dif- Clinker crusher
ferentials across the flow regula- The PYROFLOOR ® cooler can be
tor, the spring loaded plate equipped either with a hammer
Clinker crusher moves to an equilibrium po- or roller crusher, in the end or inter-
sition at a certain height mediate position. Process-wise, the
within the cylinder. This position corresponds to a well defined opening in preferred solution is the intermediate
the cylinder shell. Hence, an increase of pressure drop above the flow re- roller crusher. The alternative arran-
gulator (e. g. within the clinker layer) will increase the cross-section for the gement of a hammer crusher at the
inflowing cooling air, thus decreasing the pressure loss of this flow. Finally end of the cooling grate involves
the pressure drop changes are exactly counter-balanced, so that the total lower investment costs.
pressure drop and air flow for the complete system consisting of the flow
regulator, cassette, and clinker layer remains constant remove and so does
the air flow! By modification of certain parameters such as spring force,
plate diameter and the shape of the cylinder openings, specific response

PYROFLOOR ® grate cooler:

State of the art modular concept
The modular concept proach, assembling and installing
The mechanical design of the the cooler is very straightforward.
PYROFLOOR ® clinker cooler is This helps to keep down costs and
based on modular components. This enables easy upgrading.
approach ensures easy adaptation
of client-specific needs and require- Maintenance aspects Aeration of the PYROFLOOR ® cooler
is locally optimized
ments. By using this modular ap- Reducing maintenance costs has been
the most important requirement for the the outstanding ambition of the
specialists at KHD to find new soluti-
PYROFLOOR ®
development of the new cooler. The
whole concept has been designed ons for all of the requirements of a
with the objective of allowing for a clinker cooler. The result is nothing
period of at least two years without
any maintenance work. Grate plates
less than a truly new concept in
clinker cooler technology.
The Great Cooler
are no longer wear parts. There are
no cast wear parts. Only sealing Clients’ requirements, focusing on
related parts are to be checked and low maintenance and investment
eventually replaced. costs as well as sustained high
recuperation efficiency and plant
Conclusion availability, are met with the
From the beginning of the design PYROFLOOR ® clinker cooler to
phase to the first installation, it was a hitherto unrivalled degree.

KHD Humboldt Wedag GmbH ZAB Zementanlagenbau Humboldt Wedag India Private Ltd. OOO KHD Humboldt Engineering
Colonia - Allee 3 GmbH Dessau Mehtab House, A - 36, Mohan Mjasnizkaja ul., 24/7
51067 Cologne / Germany Brauereistraße 13 Co - op Estate, Mathura Road B. 1, Office 108
Ph.no: +49 221 6504 0 06847 Dessau-Roßlau / Germany New Delhi - 110044 / India 101000 Moscow / Russia
Ph.no: +49 340 50 29-2 13 Ph.no: +91 11 4210 1100 Ph.no: + 7 495 6 23 34 80

Humboldt Wedag, Inc. KHD Humboldt Wedag Machinery Humboldt Wedag GmbH, Humboldt Wedag GmbH Merkezi
400 Technology Parkway Equipment (Beijing) Co. Ltd P.O. Box 380 Almanya Türkiye İstanbul Şubesi
Norcross GA 30092 / USA CITIC Building, 25A Jeddah 21411 Ayazaga Mah. Meydadan Sk. No: 1
Ph.no: +1 770 810 7315 19 Jianguomenwai Street KINGDOM OF SAUDI ARABIA Beybi Giz Plaza K: 26&27 www.khd.com
Beijing / China 100004 Tel: +966 2 671 7121 Maslak 34396 İstanbul
www.khd.com Ph.no: +86 10 6500 4101 Türkiye
 PYROFLOOR ®
Concept component Target characteristic

PYROFLOOR ® walking floor bottom no conveying elements in clinker layer

active clinker distribution, red river fighting
passive clinker layer

Innovative development of grate cooler technology

aeration cassette autogenous wear protection
homogenous aeration
contact seals no stray air
no under-grate spillage
KHD Humboldt Wedag grate coolers for all capacities over have been successfully installed throughout the world. flow regulator aeration according to local requirement (3-D)
KHD Humboldt Wedag was granted the first grate cooler patent in 1936 and has since gained constant aeration irrespective of any incidents
within the layer
extensive know-how in the field of clinker cooler systems.
Now KHD Humboldt Wedag has developed PYROFLOOR ® – a new clinker cooler, which is offering a new
dimension for the cement industry.
Walking floor bottom and aeration cassette:
For the application of the walking floor principle in a clinker cooler,
This new cooler combines the best solutions for each of the two fundamental,
the design had to be engineered as an aeration floor. To meet the
mutually interacting functions a clinker cooler has to accomplish:
requirements of low wear rates on modest materials, the floor has been de-
• Clinker conveying is based on the „walking floor” principle and
signed as a cassette set - up.
• Aeration is controlled by self-regulating valves.
The basic concept incorporates the formation of a layer of stationary passive
clinker, remaining on the cassette at all times, serving two objectives:
Advantages: • provide autogenous wear protection

Better than the others: • use the passive clinker layer as a distributor sieve for homogeneous air distribution.

At the functional joint between clinker transport and layer aeration, the cassette design prevents any relative
High heat recuperation: Low wear: movement between clinker particles and metallic surfaces. There are no pushing surfaces perpendicular to the
• Decoupling of wear effects from • No more perpendicular pushing surfa- clinker movement, which would be subject to wear. In fact, a wedgeformed layer of passive clinker always
aeration ces that would be subject to wear remains on top of the cassette during the forward stroke and backward retractions of the lanes. The gross
• Wear – if any – will not influence • (Almost) no more relative movement bet- transport of clinker is created in those layers of the clinker bed adjacent to and above the passive cushion.
aeration and heat transfer ween clinker granules and metal parts
• Self-regulating aeration • No cast wear parts
• Sudden changes within the The design principle:
clinker layer are compensated Easy maintenance:
automatically • No maintenance during the production year A robust modular system
• No more fountains – optimum • No exchange of spare and wear parts for at least
aeration on the whole grate two years Contact seals: seals at all those places where air design keeps the air flow constant
The PYROFLOOR ® cooler utilizes could otherwise stray through laby- irrespective of any influence by
newly designed unique contact rinth gaps. Through this technology, mass inertia. The principal set-up
Basic principles: neither air can find its way through consists of a central shaft, which al-

Best clinker transportation and specific aeration for gaps where it should not pass, nor
can clinker penetrate between the
lows a spring loaded plate to travel
up and down within a cylindrical
maximum heat recovery cassettes and fall into the lower
grate compartment. The functioning
tube. The tube has openings of a

Clinker transportation by walking floor of all sealings is secured regardless

The walking floor principle was developed more than 60 years ago and has proven its reliability in numerous of any thermal and operational
bulk conveying applications. The principle consists of several lanes, arranged beside each other in the direction of aspects.
clinker transport. These lanes are pushed forward simultaneously and retracted in such a pattern that no adjacent
lanes are moved at the same time. The clinker bed behaves like a solid body held in place by the majority of the non Flow regulators:
moving lanes while the lane retracts beneath it. A new type of flow regulator has
been developed for the applica-
tion in movable systems. Unlike
other types of flow regulators, this

New sealing concept

• Contact sealing • Self - aligning • Perfect aeration • High heat transfer
• No leakage • Self - adjusting • Perfect process • Low maintenance
• No riddlings • All sealings identical control