Benefits of analysing kiln inlet gases

May 6, 2016 Christian Markussen

Improve your safety, operating costs, production and emissions - with a payback of less than 200 days.

Discover the benefits of analysing kiln inlet gases
For cement plant operators, the analysis of kiln inlet gas data can play a fundamental role in optimising safety and product quality, reducing down time & operating costs and limiting harmful emissions. 

100 times faster to clean – The KilnLoq’s patented One-Pipe design requires just 1-3 minutes cleaning. No other probe system on the market comes close.

In general, gas analysis gives you the chance to deal with problems and issues as they arise at source – in the process itself. Below, are a few of the most immediate ways effective gas analysis can benefit your process and put your business in shape to compete.

Kiln pyro control 
Maintaining optimal levels of oxygen in the process not only removes the risk of explosion, it also prevents a toxic build-up of carbon monoxide.

Kiln stop prevention
Downtime costs money – big time. And if oxygen, carbon monoxide and sulphuric acid build up in your kiln, production has to be stopped for at least three hours. You will also have to heat up the process again – and that is not always a smooth, stable operation. Your throughput is bound to go down, and the quality of your clinker may be affected too. With gas analysis, you simply don’t have to stop your kiln.

Optimal fuel consumption
Gas analysis helps you control your levels of oxygen so you can choose between burning fuel more slowly and efficiently for lower production costs, or burning it faster for a higher throughput and greater capacity. That gives you the flexibility to tailor your production strategy to the needs of the market – fast.

Emissions reduction
The more complete the combustion in the process, the less pollution your plant will produce. Gas analysis lets you regulate the oxygen and carbon monoxide produced by your processes at source, so you can optimise combustion and avoid using expensive anti-emissions equipment to remove pollutants at a late stage in the process.

Safety
If you are not in control of the levels of oxygen, carbon monoxide and methane in your process, you are not in control of your pyro processes – and that can have disastrous consequences for the safety of your working environment.

Clinker quality
Normally, clinker is tested for quality in the lab, two hours after the process is complete. Analysing gas such as nitric oxide while the process is still in the kiln allows you to make fine adjustments, saving you handling time, and helping you avoid simple mistakes such as over burning the clinker.

Control of volatiles
The build-up of volatiles, such as sulphuric acid in your process can cause two expensive problems. The first: any volatiles condensing on the cool raw materials as they are fed into the process will build up and cause blockages. The second: raw materials producing volatiles unchecked will get through the kiln’s brick lining and corrode the steel structure. Both require shutdown; and the second can take days to fix. Gas analysis detects the volatiles at source so you can remove them before any damage is done.

KilnLoq™ - the reliable and efficient solution
FLSmidth is recognised as a market leader in the development of gas analysis equipment and its proven KilnLoq™ system has been designed and built to provide optimum reliability and performance in high temperature, high dust operating environments.

Our KilnLoq system, with its unique one pipe probe, generates continuous gas analysis data that enables kiln operators to identify and deal with issues before they impact on the production process.  

Want to learn more about this accurate and easy to maintain system?  Watch our new KilnLoq video>


 

Read about the KilnLoq system here >

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