Energy efficiency –Precise and reliable gasmonitoring in rotary kilnsFLK gas sampling system monitors CO and O2

for burning efficiency

The Siemens FLK

sampling system

provides the

information to

control the air / fuel

mix accurately

to increase burning

efficiencies in the

rotary kiln.

Rotary kiln gas analysis

Continuous analysis of oxygen (O2),

carbon monoxide (CO), and nitrogen oxide (NO) in the rotary kiln is essential for the quality of the produced cement clinker, the efficient use of fuel, and the protection of the environment from toxic emissions.

Application demands and our solution

Siemens FLK gas sampling system

• gas temperatures up to 1400 °C• dust concentration up to 2000 g / m3

• high alkali, sulphate, and chloride content

• high mechanical stress resulting from falling material or inflowing raw meal

Production capacity

has been enhanced

by up to 20 %, lower

energy consumption

and reduced grind-

ing costs.

Accurate chemical additions

Grinding aids are chemical additives that improve grinding efficiency, reduce the cost of production, and improve the qual-ity of cement. To improve the distribution of additives, it is proportioned with anoth-er carrier liquid. With final dosing rates of between 0.04 % and 0.06 %, highly accurate and repeatable measurement is required.

Application demands and our solution SITRANS F C MASS

• high accuracy at low flow rate• ability to measure non-conductive liquids• low maintenance required

Energy efficiency –Reducing the energyconsumption of the crusherLevel measurement optimizes crusher performance

Siemens ultrasonic

level measurement

provides accurate

and reliable level in

the crusher under

the most difficult

conditions, such as

dust, noise and me-

chanical vibrations.

The crusher

Before going to the screening and blend-ing process, the raw material is crushed to reach the required product size. To optimi-ze efficiency it is essential to choke feed the crusher without overfilling. Choke feed-ing a crusher improves control of product size distribution, reduces wear and maxi-mizes throughput.

Application demands and our solution

SITRANS LU

• combined with an XPS remote trans-ducer has proven to be to most reliable longterm solution

• transducer resistant to noise, vibrations, impact and dust

• no electronics in the process environment • easy installation, no maintenance• non-contacting level technology

Aggregates

Environmentalresponsibility –Compliant environmentalmonitoring for the stackContinuous emission monitoring with the ULTRAMAT / OXYMAT Siemens Gas Analysers

Siemens Process

Analytics delivers

a comprehensive

range of approved

solutions, meeting

local directives and

providing the lowest

cost of ownership.

Exhaust gas at the stack Burning of fuels such as coal, oil, or waste in the kiln generates exhaust gas that can be released into the atmosphere through the stack. International and national au-thorities specify concen tration limits for dust and certain chemical compounds that must not be exceeded.

Application demands and our solution

Siemens Gas Analysers

• continuously operating Siemens Gas Analysers

• CO, O2, NOX, SO

2 analyzing; additionally

THC, HF, HCL, NH3, Hg

• continuous monitoring of dust• High operating reliability, availability and

service life• Minimal maintenance and spare parts

requirements

The Siemens

SITRANS P DSIII

differential pressure

transmitter mea-

sures relative airflow

and filter media

differential pressure

providing critical

information for bag

house control.

Bag house performance Reduction of particulate emission to the atmosphere is a key issue in any cement plant.

For optimal dust collection, the filter is pe-riodically maintained through reversed air in-situ cleaning. This process is triggered when the differential pressure across the filter rises above a predetermined level.

Application demands and our solution

SITRANS P DSIII

• intelligent cleaning when necessary• long-term stability of kiln operation• prevention of device failure through

predictive maintenance• meeting emission constraints

Using Siemens

SCALANCE

industrial wireless

communication

reduces the cost of

installation, wiring,

maintenance, and

repairs significantly

with a fast return on

investment.

The quarry The quarry is often a very remote area. For an optimum supply of raw material and for inventory management, it is important to integrate the data from the quarry into the control system.

Wireless communication of this data has numerous advantages over wired data transmission.

Application demands and our solution

Siemens SCALANCE W

• cost effective and reliable solution.• long-distance secure data transmission• seamless integration into the plant’s

control system• no cables, no risks of physical damage• cost effective and reliable solution

Measurement and

control equipment

from one manufac-

turer offers a fully in-

tegrated system that

optimizes flotation

cell performance.

Flotation process

The flotation cell is used within the mining industry as a process for separating minerals from the raw material.

The flotation cell would ideally be a bal-anced process where the reagent dosing rate, aeration, and froth depth remain con-stant. To achieve this, precise monitoring and control are required.

Application demands and our solution

Siemens Process Instrumentation

• reliable froth level measurement• accurate reagent dosing flow rate• control of pulp retention time• control of air addition rate

The in-situ

measuring principle

of the Siemens LDS 6

provides safety-

critical information

in real time for

immediate action.

Self-ignition in coal silos A major concern with coal silos is the risk of partial self-ignition of the coal. This is difficult to predict as the condition is dependent upon several factors such as moisture content, pressure, and tempera-ture.

However, early detection can be achieved by monitoring for increased CO levels at the top of the silo.

Application demands and our solution

LDS 6 in-situ gas analyzer

• measurement of information in real time• no calibration required• no cross interference with other gases

and moistures

Plant Safety –Fast and reliable safetysurveillance in coal silosLDS 6 in-situ laser gas analyzer monitors CO in real time

The SITRANS LR460

level radar and

Pointek CLS 300 level

switch are proven to

be the most reliable

level management

instruments for the

cement industry.

Silo level management

The cement production process uses silos for raw materials, homgenization, clinker storage and finished cement. Inventory management is vital in ensuring that the process is not interrupted.

Continuous level measurement with 100 % availability increases the productivity of the plant and allows a more advanced level of automation. Reliable redundant high level switches prevent overfilling of the silo in any condition and guarantee safe operation.

Application demands and our solution

SITRANS LR460 level radar and Pointek CLS 300 level switch

• dusty environment in most silos, espe-cially in raw meal silos during filling, emptying, and aeration

• high temperatures of more than 200 °C in clinker silos

• sensors mounted in harsh environment liable to weather conditions, material build-up, and mechanical stress

Plant Safety –Reliable silo levelmanagement for safeoperationsMeasuring dusty solid materials with Siemens levelinstruments under all conditions