Cement Production: Focus on what really counts
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.
Key facts
65-75 %
energy cost
of the overall costs are not uncommon within cement manufacturing. But there are ways to optimize the process.
What you can do
©Endress+Hauser
©Endress+Hauser
©Endress+Hauser
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.
- A capacitance point level rope probe is used to prevent overflow of bunkers for raw material
- A vibration level switch you can help you to avoid overspills in clinker silos.
©Endress+Hauser
Kiln burner control and fuel oil dosing
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
©Endress+Hauser
Clinker cooler monitoring
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:
- Differential pressure sensors for metering and monitoring cooling air consumption
- Flow meters for air cooling and high temperature radar level sensors for clinker bed height monitoring to regulate cooler grate speed and air volumes
- Non-intrusive blockage sensors for material collection silos under the clinker cooler grate
- Non-invasive radiometric scale for mass flow on clinker screw conveyors or belt feeders (indicates clinker density and infers free lime levels)
©Endress+Hauser
Cyclone preheater instrumentation
Cyclone preheaters need to be monitored to control the blending of the the raw meal and to prevent blockages which could result in costly down-time.
Our expertise in the field
Apart from temperature as a base parameter for overall efficiency , measuring pressure and actual build-up can help detecting blockages.
- Latest in high-tech, abrasion-proof alloy thermocouples with vibration-resistant electronics for long-life temperature monitoring
- High-accuracy, thermal, shock-resistant sensors for cyclone chamber pressure control
- Non-invasive cyclone buildup and blockage detectors
Benefits
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.
Key facts
145,000+
smart level sensors in cement silos worldwide
Key facts
60+
years of experience in measurement instrumentation
Key facts
10 million
devices installed worldwide
How we can help
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