ProKiln GAC400

Gas sampling system for kiln and calciner

The cement industry has seen an immense increase in alternative fuels in recent decades. This has benefits for energy efficiency and environmental impact but also presents new challenges that have implications for the kiln inlet measurement in addition to the process.
ProKiln is the 4th generation of ABB for gas sampling at the kiln inlet and calciner in the cement industry. The premium product has been developed to meet the changing process conditions in cement plants due to the increased use of alternative fuels.



The premium solution for cement plants with increased use of alternative fuels

Cement production is highly energy  intensive and the majority of plants worldwide are
continuously seeking to increase use of alternative fuels to reduce the impact on the
environment and increase process efficiency. According to the European Cement Association there is no technical limitation for cement plants to increase use of alternative fuels up to 95%. With the industry moving rapidly in this direction, despite clear economic and environmental benefits, it also presents new challenges for process and equipment.
To meet the changing process conditions, ABB and FLO2R have joined forces to offer a premium product that supports cement plants in achieving their objectives. With 60 years’ combined experience, the 4th generation kiln inlet solution of ABB has been developed. 

ProKiln – The next generation is powerful!

ProKiln consists of a control unit, cooling unit and a retraction unit. Having two air blasters equips the retractor with a powerful cleaning of the probe tube. In combination with the unique 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 sample and dust a two-layer filter is embedded inside the probe and can easily be cleaned via the air blasters. Furthermore, the thoughtful design allows a manual cleaning and the conduct of maintenance activities without specialist knowledge, leading to an availability of more than 95%.
In addition, the solution is available in a double probe configuration to support cement plants on their journey to 100% availability

The unique features of ProKiln:

• Powerful cleaning with 2 air blasters
• Filter in the tip of the probe ensuring no mix of sample and dust
• Limiting direct dust flow based on tip shield
• Innovative and unique nozzle design
• Thoughtful design allows an easy manual cleaning
• No moving parts
• User-friendly operation via touch panel
• Combinable with AO2000 system and 3rd party analyzers
• Available as single and double probe configuration



ProKiln consists of the following three modules

• Retraction unit with an electrical motor and chain-driven water-cooled probe
• Cooling unit with a heat exchanger and cooling water circulation pump
• Control unit with industrial controller including color touch panel

Retraction Unit

• Available as single or double probe
• Probe length of 1.5m / 2.0m / 2.5m / 3.0m /3.5m
• Electrical motor by default
• Pneumatic motor with air tank to cover power failure (optional)
• Automatic oven flange closure
• Cooling water tubes
• Air blaster tubes
• Heated sample gas line

Control Unit

The menu-driven industrial controller includes a touch panel and operates the complete system. It allows configuration of cleaning cycles, limit values and periodical sampling according to the operators needs, without any complicated PLC programming.

Cooling Unit

Cooling of the sample probe is mandatory due to the prevailing conditions. ABB’s cooling system uses a non-pressurized water circuit with an open vessel for safe and environmental friendly cooling.

• Capacity water tank: 300l
• Controlled temperature 75 to 85°C (167 to 185 °F)
• Circulation 6 to 7 m3/h
• Drinking water quality, anti-freeze agent necessary at ambient temperature < 0 °C (32 °F) or/and optional heater in water tank.


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