Easily meet the specific and complex demands of your customers
Facing volatile commodity prices on the one side and complex customer demands on the other, the need for optimized processes within the cement industry has never been higher. Think for example of the energy costs in the clinker manufacturing process, which can represent up to 75% of the variable costs. But to efficiently lower your expenses without compromising the quality of your products, accurate process data derived from reliable instruments is key.
65-75 %
energy cost
of the overall costs are not uncommon within cement manufacturing. But there are ways to optimize the process.
Whether you are managing a project, automating a fuel handling system, selecting instruments for your clinker process or packaging a NOx gas cleaning solution for your environmental compliance program, our experienced process automation consultants can handle all measurement and control requirements of fully-integrated cement plants:
Raw meal and clinker silo monitoring
Kiln burner control and fuel oil dosing package
Clinker cooler monitoring
Cyclone preheater instrumentation
Storage and dosing of additives
Applications
Raw meal and clinker silo monitoring
In order to keep production going it is necessary to continuously monitor stock levels in the raw meal and clinker silos. As storage vessels come in many shapes and sizes, level monitoring can be a challenge.
Our expertise in the field
Endress+Hauser offers many different level monitoring technologies and solutions, designed for challenging environments like dust and abrasion.
Our 80 Ghz radar level sensor is best suited for measurements in high silos or bunkers. It features a small beam angle and Multi-Echo Tracking evaluation.
Pyroprocessing is generally regarded as the heart of cement production. It is the stage in which most of the operating costs of cement manufacturing appear, and is also therefore the area where most of the opportunities for process improvement exist.
Our expertise in the field
The main parameter for these processes is naturally temperature. By monitoring it, you can ensure a consistent product quality and optimize fuel consumption.
For temperature measurement in the upper cyclones of the preheater, use a thermocouple with an advanced ceramic thermowell made of Silicon Nitride.
For the bottom cyclones, we recommend thermometers with a bar stock thermowell made from a Nickel Cobalt which offers unparalleled resistance against aggressive gases.
Coriolis flowmeters optimize the burner by regulating the mass flow of oil to the burner and provide the oil heating system with online temperature and viscosity measurements
The clinker cooler is one of the most critical applications in cement production as the rate of cooling can be critical to the clinker quality and overall performance of cement.:
Our expertise in the field
Thanks to our comprehensive portfolio we can offer a whole clinker cooler monitoring package all from one source. This includes:
E+H industry consultants have together with our customers achieved remarkable results and improved plant optimization whilst maintaining high levels of operational safety in many industry sectors like precious metals, cement and steel production. Apart from our technical expertise and the industry optimized product portfolio the basis for such success is our business creed. We believe in building long-lasting relations with customers and not just short term profits.
145,000+
smart level sensors in cement silos worldwide
60+
years of experience in measurement instrumentation
Total energy cost can represent 65-75% of variable costs in the process. To save energy, we help improve clinker production with integrated online monitoring and optimized fuel management.
Water, beverages, dairy products, chemicals or pharmaceuticals have to be analyzed every day. Choose the device best suited to your process needs from our comprehensive product portfolio.
Flowmeter
Flowmeter
Water, natural gas, steam, mineral oil, chemicals are some of the fluids that have to be measured day in, day out. Select the flowmeter best suited to your process needs.
Level
Level
Continuous level measurement and point level detection in liquids and bulk solids
Pressure
Pressure
Powerful instruments for process pressure, differential pressure, level and flow.
Software
Software
Apart from all relevant measuring and system technologies, we also offer appropriate software for all branches of industry that provide to run your operating processes at its full potential.
System products
System products
Applicator
Temperature measurement
Temperature measurement
Thermometers and transmitters for the process industry
Instrumentation Services
Instrumentation Services
Maximize plant performance, minimize OPEX, increase uptime, all with compliance. Partner with Endress+Hauser instrumentation services.
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