How to ensure uninterrupted process control in cement rotary kilns

Case study | July 24, 2024

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.

Cement production is highly energy intensive, and most 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 percent. With the industry moving rapidly in this direction, despite clear economic and environmental benefits, it also presents new challenges for process and equipment.

ABB's ProKiln patented technology sets new standards in measurement technology, ensuring accurate measurement values without interference from dust or process gas mixtures.

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

In its 4th generation, ABB’s ProKiln is a gas sampling system for kiln inlet and calciner in the cement industry. The system was specifically developed to meet the changing process conditions in cement plants due to the increased use of alternative fuels.

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 percent. In addition, the solution is available in a double probe configuration to support cement plants on their journey to 100 percent availability.