Cement Process is mainly classified in four segments
- Crushing area
- Milling area
Pyroprocessing is a process in which materials are subjected to high temperatures (typically over 800 °C) in order to bring about a chemical or physical change. It consists of three stages: Preheater, Kiln & Cooler.
Preheaters are used in industrial dry kiln cement production plants to heat the raw mix and drive off carbon dioxide and water before it is fed into the kiln. Temperature typically used from 100°C to 300°C
The Kiln is the heart of the plant – what an entire cement plant is dimensioned around, and where most of the final chemical reactions take place. The kilns play a key role in ensuring optimal quality clinker. The rotary kiln consists of a tube made from a mild steel plate and slowly rotates on its axis. Rawmix is fed in at the upper end, and the rotation of the kiln causes it to gradually move downhill to the other end of the kiln. Kiln size & Dia is dependent on the capacity of the production of the plant.
There are many different types of refractory brick and they have to withstand not only the high temperatures in the kiln but reactions with the meal and gases in the kiln, abrasion and mechanical stresses induced by deformation of the kiln shell as it rotates. The range of kiln temperature is between 700ºC to 1800ºC.
The burning zones are in a more aggressive environment and So, different parts of the kiln are lined with different types of bricks in the refractory. Severe changes in the temperature may damage the refractory lining. The cost of refractories is a major expense in operating a cement plant, kiln stoppages are avoided as far as possible.
Hence accurate temperature monitoring therefore plays an essential role in quality control of the cement, Avoid refractory failure and to maintain the energy efficiency of the kiln.
AST Solution: For Kiln Burning Zone
AST A450C Two color pyrometer is most recommended for cement industry environments like dusty which measure accurate temperature of the KILN BURNING ZONE. 2 color pyrometers overcome the obstacles like dust & fumes and focus on the target for reading.
The Kiln Pyrometer measures an object’s temperature by calculating the energy ratio at two different wavelength bands. A wide band detector with spectral range from 0.7 to 1.15 μm is used in A450C+
The wide temperature range of the A450C+ 2-colour model used for burning zone temperature measurement is from 600-1800°C.
Rugged Water cooling jacket and Air purge with quartz protection window makes the system suitable for harsh environment applications.
A 450C+ has real time color video for data monitoring in a burning zone measuring temperature and emissivity is displayed on the television screen. Pyrometer offers RS 485 interface, Analog output 0..20mA & 4..20 mA
“InfraSoft” software offers possibilities to connect 3 pyrometers simultaneously for parameter settings, view real time graph, offline graph and to evaluate measuring data.
The Clinker Cooler is used to cool the clinker. After cement is dried by being put through a rotary kiln and converted to a clinker, it needs to be cooled. The rate of cooling tunnels are used to reduce the temperature of the clinker from over 1250°C to a workable 100°C. These tunnels typically use forced draft fans to push the cooled air through the clinker. It is essential to monitor the clinker for rogue hot inclusions before it reaches the conveyor belt and causes damage.
AST Solution: For Clinker Cooler
EL50 is an economic digital IR Pyrometer from E series with extended sensing head in 4 wire technology for non-contact temperature measurement between 0°C to 800°C. The pyrometer comes with wide angle optics to cover more area, fast response time within milliseconds and PC software for remote parameterization.