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SCANNER SYSTEM DESCRIPTION is a shell temperature monitoring system for rotary kilns. It uses a high-resolution infrared line scanner, connected through electronic hardware to a computer located in the control room (see figure 1). The rotating movement of the kiln allows monitoring the whole surface of the shell, thus obtaining a complete scan with each turn.

TEMPERA

F igure N° N° 1: Block Diagram

Radiation data provided by the line scanner is converted to temperature values through software, which takes into account the atmospheric absorption effect and the thermal emissivity of the kiln, as well as the characteristics of the detector. Temperature data is displayed in a computer screen as thermal maps (thermograph).

The line-scanner detects the infrared radiation emitted from a narrow area of the shell that subtends an angle of 90 ° or 120º horizontally (depending on the scanner being used). The system generates more than 1000 data points for scan. The scan takes only few milliseconds and occurs 20 (40 or 80 optional) times per second (see figure 2).

Figure N° 2:

Infrared line scanner measurement principle description

SCANNER TEMPERA TEMPERATURE MONITORING SYSTEM FOR ROTATORY KILN

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TECNOLOGÍA IINTEGR AL S S. A A. Soluciones Tecnológicas Avanzadas Empresa Certificada ISO 9001:2008

FUNCTIONAL CHARACTERISTICS ON-LINE INFORMATION

Any unusual thermal behaviour on the kiln shell will be quickly spotted by the operator thanks to the information displayed onscreen, which will allow him to promptly take the right corrective actions.

ANALYTICAL CAPABILITY TEMPERA stores

all the information automatically. This as well as a series of functions loaded into the system, allow a detailed analysis of the thermal conditions of the kiln. One of these features is to schedule in advance the necessary repairs of the kiln. It being able to virtually "see" the refractory bricks wall avoids expensive brick stocking because the state of the internal refractory wall after a campaign is known before opening the kiln.

HISTORY

The TEMPERA system automatically stores information from the shell s thermal maps, as well as hourly averages, maximum and minimum. This information is employed, by using specific commands, to show the recorded information on screen, at different dates. Distinguishing between different data allows evaluate and optimise the operating conditions of the kiln. It also helps in the detection of hot spots, falling of refractory bricks, formation of rings, etc. ’


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REFRACTORY ADMINISTRATION

Displaying on-screen the type of refractory wall being used in the kiln, gives the operator access to information regarding changes made, elapsed operation time, last measured thickness, installation date, etc. These data, plus the temperature information, allows determining the condition in which the refractory wall is, and facilitates decisions like the campaign s extension, or the overall dimension of necessary works in order to properly maintain the kiln. ’

KILN POSITION ENCODER

In order to take advantage of the analytical options of the program, TEMPERA can perform temperature measurements in synchronisation with the rotational movement of the kiln by using a kiln position encoder module. With this set-up it is possible to correlate the temperature measurement with the position of the shell kiln independently from the fluctuation of the rotational velocity of the kiln.

TIRES

The system is capable of detecting slippage anomalies in each one of the tires. To achieve it, TEMPERA measures and keeps updating on-screen, the slippage value in millimetres, for each revolution of the kiln. Information is saved, being able to obtain hourly averages and daily and monthly trends. Should a tyre displace out of range (preconfigured by the operator), then the alarm for that tire is triggered.

COOLING FANS AND ALARMS TEMPERA

permanently shows a graph of extreme temperatures (maximum and minimum) and simultaneously displays the limits for the different zone or cooling fan alarms. The tolerance level of each alarm blinks if the value of the parameter being used to monitor a given zone is out of its preset value (see Figure 3). The system allows the configuration of up to 10 distinct alarms for each kiln or 25 cooling fans, using different areas or zones and setting the upper and lower limits individually.


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NETWORK THERMAL MONITORING TEMPERA-NET has

the ability to connect to the computer network used in the plant, which allows the real-time display of the kiln s monitoring process and perform thermal condition analysis from any office inside or outside the plant. ’

ADVANTAGES ! ! ! ! ! !

Maintenance cost reduction Operational costs reduction Increase in productivity Safe operation Management capacity improvement Historical analysis of the kiln

TEMPERA is

a powerful tool for kiln thermal management, providing important information that allow the safe operation of the kiln along the whole period of production, also the efficiency optimisation of the production process, and the programmed maintenance of the refractory wall reliably and at a minimum cost. The time required to regain the initial investment varies strongly with the type of kiln and the degree of control on the clinker production process. In most cases, the savings generated by the longer lasting of the refractory wall, extended production campaigns without not-programmed halts and optimised kiln operation, justify the employment of TEMPERA since the first months of use. Alexandre Chriguer Application Engineer ECIL Produtos LTDA - Piedade - SP Tel. +55 15 3244.8052 | Cel.+55 15 9630.7096

e-mail: [email protected] / Visite nosso site: http://www.ecil.com.br


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