Friday, June 24, 2016

Dust Monitoring Applications in Cement Manufacturing

Cement Plant
Cement plants have many areas requiring dust monitoring 
Cement manufacturing presents many applications and challenges for dust monitoring. There are several segments of the process that commonly provide the majority of dust monitoring applications. A unique design dust monitor, manufactured by Sintrol which uses Inductive Electrification technology is an ideal solution for many of these applications.

The monitor’s measurement is based on particles interacting with an isolated probe mounted into the duct or stack. When moving particles pass nearby or hit the probe a signal is induced. This signal is then processed through a series of advanced algorithms to  filter out the noise and provide the most accurate dust
Sintrol dust monitor
Sintrol dust monitor using
Inductive Electrification technology
measurement output. Classic triboelectric technology is based on the DC signal, which is caused by particles making contact with the sensor to transfer charges. Compared to DC based measurements, the Inductive Electrification technology is more sensitive and minimizes the influence of sensor contamination, temperature drift and velocity changes. By using the Inductive Electrification technology it is possible to reach dust concentration measurement thresholds as low as 0.01 mg/m3.

Areas Where Dust Monitoring is Found in Cement Manufacturing:

Crushing and Milling - In the raw materials handling process,  filtration systems are utilized to control emissions in the quarrying process of the plant. To minimize the loss of limestone and other materials that are fed into the kiln, dust measurement systems provide plant operators feedback on the deterioration or breakage of the bags in the filter. Monitoring the performance of these  filter systems also reduces the maintenance costs and downtime in plant operations.

Preheater and Rotary Kiln - In both dry and wet processes, materials go through some form of a heating process creating gases released on both ends of the kiln. There is typically a dust removal system and an emissions stack at each end. Filter leak detection provides an early warning that product is releasing into the atmosphere. Trend monitoring in common ducts and emissions monitors can provide trend data that enables plant operators to optimize the plant’s  filtration systems.

Clinker Mill - Once the clinker has been produced and passed into the cooling systems, it is important to maximize the production of cement in the plant. As the gases are passed through a dust removal system, the trapped particles are returned to the clinker silos as product rather than released into the atmosphere as loss. Particulate measurement in the outlet ducts of these  filtration systems is essential to optimizing the output of the plant. Identifying a broken  filter at the earliest stage allows plant operators to react quickly to breaches in the production output.

Packaging - In the last stage of production,  filtration units are used as product is transferred to packaging and shipping. Similar to the previous stages of the process,  filter leak detection and trend monitoring provides plants with tools to identify when cement is being released into the atmosphere. Dust monitors provide the perfect tool to ensure that the cement manufacturing process is able to optimize its total output.

Dust Monitoring Solutions Available for Cement Manufacturing:
leak detection
Sintrol leak
detection monitor

Filter Leak Detection - In each area of the process where there are single or multiple compartment
baghouses, Sintrol monitors are the perfect solution to provide notification to the customer of deterioration or breakage of the  filter bags. This provides early detection for the customer that excess particulate matter is in its process and releasing out of the stack. The monitors are largely maintenance free devices that can measure dust levels as low as 0.1 mg/m3.

Trend Monitoring - In many larger or combined outlet ducts, a continuous trend measurement is preferred to get a constant reading on dust levels in the process. A dust monitor allows the customer to identify increasing trends in the dust levels and possibly identify sources of extra pollutants in its process.

For plants that use Electrostatic Precipitators (ESP), monitors are available that allow the end user to
Sintrol ambient dust monitoring
Sintrol ambient
dust monitoring
get a continuous trend measurement in 4–20 mA output after an ESP. The user can learn about the efficiency of its ESP, optimize the hammering process, and make adjustments to maximize the efficiency of the filter system.

Emissions Monitoring - For each stack in the plant, monitors can be calibrated to provide extremely precise readings for actual emissions amounts. These virtually maintenance free monitors are a less expensive and more reliable alternative to the traditional opacity monitors that have been used historically.

For more information on any dust monitoring application, contact:

Array Automation
1178 E. Cliff Road
Burnsville, MN 55337-1577
Phone (800) 761-1749
Fax (612) 861-4292