The premium solution for cement plants with increased use of alternative fuels
Cement production is highly energy intensive, and most plants worldwide are continuously seeking ways to reduce their fuel consumption and the impact on the environment, while increasing the clinker throughput. A typical way of reducing fuel costs is to substitute it with alternative fuels, namely waste materials from other industries or household waste. According to the European Cement Association some cement plants had already increased their substitution ratio up to 95% by 2020. With the industry moving rapidly in this direction, despite clear economic and environmental benefits, it also presents new challenges for process and equipment. By rule of thumb, if a cement plant can reduce the oxygen concentration in the kiln by 1%, the fuel consumption and CO
2 emissions will also reduce by 1% and the clinker throughput will increase by 1% to 2%. Accurate and reliable measurement of gas concentrations inside the kiln is therefore absolutely necessary.
To meet these challenges, ABB and FLO2R have joined forces to offer a product that supports cement plants in achieving their process and environmental objectives. With more than 60 years’ combined experience, the 4th generation kiln inlet solution of ABB has been developed.
ProKiln – The next generation is powerful!
ProKiln has been designed radically different than its predecessors on the market. It consists of a control unit, a cooling unit and a retraction unit. The probe retractor is equipped with two air blasters for powerful cleaning of the probe tube. In combination with the unique filtering-nozzle design, the pressurized air is directed in different streams to ensure the most effective cleaning of the probe tip. To avoid a mix of process gas and dust, a two-layer sinter-metal filter is embedded inside the probe and can easily be cleaned via the air blasters, leading to an availability of measurement values of more than 95%.
Optionally, the solution is available in a double probe configuration which allows the use of one probe while the other one is being cleaned and the possibility to reach 100% availability of measurement values.
Furthermore, the thoughtful design also allows for a manual cleaning and the conduction of maintenance activities without specialist knowledge.
The unique features of ProKiln:
- Double air blaster cleaning: extremely powerful, simple and well known as an effective solution to the cement industry.
- Extremely sturdy mechanical design: provides protection against material impact in the kiln inlet area, both inside and outside the process.
- No rotation or moving parts inside the probe: prevents jamming of mechanical parts.
- Protected sample filter in the tip of the probe: prevents probe blockages by separating dust and process gas as soon as it enters the probe.
- Patented 5-stage blow back system: provides low pressure loss for an extremely effective cleaning in less than 60 seconds.
- Simplicity of design and well-known solutions: anybody in the plant can service it.
- Connection flexibility: can be integrated into ABB’s AO2000-System gas analyzer or with 3rd party gas analyzers.