17/04/2015 Clinkerburninginthecementprocessoftheprimariesindustry|Endress+Hauser

Optimize clinker production

performance
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.

Endress+Hauser

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Benefits at a glance
Significantly reduces energy costs
Prevents blockages in the preheater cyclones
Accurately controls kiln chemistry
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 1
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

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17/04/2015 Clinkerburninginthecementprocessoftheprimariesindustry|Endress+Hauser

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 65 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
Measuring a portion of the kiln gases via bypass to avoid blockage
CO2 gas emission measurement, NOx gas cleaning and desulphurization
Achieving clinker cooling by cross-flow air blown through a clinker layer

Read the full clinker production story

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