Just benefiting

------The analysis of emissions from cement rotary kilns is essential for ensuring the production rate of cement. Only through continuous analysis of kiln gases can the true situation of the combustion process be understood.

System composition, functions, and characteristics

------The sampling system is installed adjacent to the feeding room of the kiln and consists of three parts, as shown in the following picture (taken on site at Hebei Jinniu Energy Xingtai Cement Plant).

------Gas sampling probe with automatic retraction device, dust filter, and compressed air intake valve assembly, liquid air heat exchanger with fan and circulation pump. A programmable control unit used for blowing and monitoring the operating status of the system.

technical challenge

------Due to the high temperature of the kiln reaching 1400 degrees Celsius, the dust concentration in the kiln gas is high and contains substances such as strong alkalinity, sulfur, and chloride, making conventional sampling equipment unusable.

------Because conventional sampling probes are water-cooled, their achievable operating temperature is lower than the dew point of the exhaust gas. The low working temperature causes condensation on the surface of the probe and dust filter, and the sediment and corrosion in the water cooling system shorten the service life of the filter and probe. Resulting in a significant amount of manpower and material resources being spent on maintenance without achieving the desired results.

High reliability and low maintenance costs

------

A special heat transfer liquid and an electrically heated dust removal filter enable the system to operate normally at temperatures up to 230 ° C, effectively eliminating condensation in the sampling equipment. In addition, the compressed air automatic cleaning system ensures the cleanliness of the probe, dust filter, and gas path. Compared with conventional sampling systems, CEMAT GAS requires much less maintenance and has a longer service life. If the manufacturer's recommendation is followed to check the probe daily, this system can be used continuously for three months without maintenance.

Application Examples

------The SIEMENS CEMAT GAS system has been widely used in over 40 cement industries due to its performance. It officially entered the Chinese market in 2003 and was successfully applied in the cement plant of Jinniu Energy Co., Ltd. (a listed company) in Xingtai City, Hebei Province. The factory has advanced technology and fully adopts Siemens process control technology, with a daily output of 2000 tons of cement. Previously, due to the inability to solve the sampling problem well, the composition of kiln gas could not be measured, and advanced control systems could not play their due role due to the lack of effective real-time data.

------After the CEMAT GAS system was put into use, the composition of CO, SO2, and O2 in the kiln gas was monitored in a timely and accurate manner. The Xingtai Cement Plant adopted two sets of CEMAT GAS systems, which were installed at the top of the kiln feed and preheating tower respectively, thus truly achieving:

• Control the device to achieve maximum efficiency
• Reduce fuel costs
• Ensure product quality
• Timely detection of abnormal working conditions to avoid shutdown and maintenance
• Reducing emissions and environmental pollution is beneficial for environmental protection