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    Endress Hauser Optimize clinker production performance

    2016/9/9      view:

    Integrated online monitoring and optimized fuel management improves clinker production performance

    Cement manufacturing is an energy intensive activity and the choice and mix of primary and alternative fuels affects both the environmental impact and economics of the process. Total energy cost can represent 65-75% of the variable costs in the process. To save energy, modern cement plants preheat the mix of raw materials before they enter the kiln. In addition, secondary burning points are installed using alternative fuels to reduce energy output.

    Measuring the temperature and pressure of the lubrication oil of the cement kiln drive's barings.©Endress+Hauser

    Benefits at a glance

    • Significantly reduces energy costs

    • Prevents blockages in the preheater cyclones

    • Accurately controls kiln processes

    • Optimizes burner performance

    • Reduces toxic waste gas emissions for compliance

    Your challenge

    The pyro-processing stage is generally known as the heart of the cement making process. It is the stage in which most of the operating costs in cement manufacturing appear and is also where most opportunities for process improvement exist. The main challenges at this stage in the clinker production are preventing blockages in the preheater, measuring the process accurately and maximizing production in this hot and rough environment.

    Our solution

    For the best outcome in the clinker production process, Endress+Hauser offer an integrated package that optimizes energy efficiency. The right combination of instrumentation (Cerabar S, Omnigrad S, Deltabar S, Solicap S/Soliwave M, Micropilot FMR57, Gammapilot M) makes all the difference. Also, our all-inclusive service portfolio helps to support you locally to secure the availability of your plant.

    Application details

    • Blockages in the cyclone are detected using the Cerabar S pressure sensor

    • Process temperature measurement with the Omnigrad S NiCo (Nickel Cobalt) or SiN (Silicon Nitride) thermocouples which are fitted with fast response data transmitters

    • Pressure drop measurement at rotary kiln head with Deltabar S differential pressure transmitters

    • Limit monitoring at the cooler outlet funnels with capacitance high-temperature Solicap S probes or Soliwave M non- intrusive microwave sensors

    Optimized package for kiln fuels management

    • Oil tank level measurement with Micropilot M free space radar

    • Mass flow measurement of heavy oil with Promass F Coriolis

    • Memograph M RSG40 Steam boiler monitoring for waste oil heating

    • Prosonic S ultrasonic system for coal level measurement in bunkers

    • Levelflex M guided level radar for hazardous secondary fuel tanks

    • Level limit detection of secondary fuels with Soliwave M microwave barrier

    • Natural or bio gas measurement with Promass Coriolis or T-Mass thermal flow meter

    Key performance indicators to keep the process running

    • Measuring material build up the preheater chambers to prevent blockage

    • Accurate regulation of temperature and pressure in each cyclone chamber

    • Calculating the retention time of clinker in the preheater and in the kiln

    • CO2 gas emission measurement, NOx gas cleaning and desulphurization

    • Achieving clinker cooling by cross-flow air blown through a clinker layer