In cement production, rotary kilns are widely used to convert raw material into cement clinker. Using high temperatures to initiate chemical and physical reactions can cause serious damage to the furnace. Therefore, protecting the furnace shell is very important to extend the life of the equipment and avoid major repairs. Mantle Scanners are used to monitor the temperature of the crust in real time, ensuring maximum operating reliability of the plant.
Kiln Shell Monitoring: Preventing Cement Plant Outages Due to Hot Spots
Tasek cement plant in Malaysia aims to monitor the overall temperature of the 500 tpd capacity rotary kiln no 3 and ensure there are no interruptions in production due to hot spots. The cement plant has a complex layout with many poles and pillars masking the shell. Part of the bakery is also located under a building. These obstructions prevent the infrared scanner from seeing the entire oven shell and create shadows. Therefore, the plant must find a solution to enable temperature monitoring even in difficult-to-visible areas of the oven.
Shadow Area Monitoring
Customized infrared (IR) scanner configuration provides full furnace temperature monitoring, eliminating shadows through advanced thermal image recombination capability. The best thermal monitoring solution for the Tasek cement plant includes three Kilnscan Mantle Scanners, each with a 140° wide field of view.
While the first scanner measures the temperature of the part of the furnace inside the building, the second and third scanners aim to scan the same part of the furnace and specifically address the shadow areas along that part of the furnace. The thermal image is reconstructed by combining data from these two scanners, eliminating shadows to provide excellent full viewing of the shell.
Remote Oven Shell Temperature Monitoring with User-Friendly Software
An integrated interface shows all relevant thermal properties such as 3D thermal profile, brick and cladding thickness, refractory management, furnace rotation speed, ring slip monitoring, heat loss calculation and more. The software is designed for simple installation and use to maximize user experience. It provides accurate alarms on critical parameters such as hot spot detection and brick and veneer thicknesses.
Thanks to historical data management, operators can track temperature trends, estimate the lifespan of the refractory material, and make replacement/overhaul plans with minimal disruption.
HGH Kilnscan is the ideal kiln shell scanner providing high performance and flexibility to technically demanding cement plants. Robust and highly flexible, the Kilnscan is designed to fit any oven configuration, including multiple shades, tall ovens and limited free space. It is part of the temperature monitoring equipment that every cement plant should have.
