Cement Industry

Importance of Dust Monitoring

Having researched hundreds of installations worldwide in the cement industry, an understanding has been developed that will enhance the cement manufacturing process for customers, which offers a solution for regulatory requirements and process optimization. Several segments of the cement industry process have typically provided the majority of dust monitoring device applications. Below are a few of the main areas where dust measurements may greatly increase efficiency:

1. 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 detioration 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.

2. 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.

3. 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.

4. 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. Sintrol monitors provide the perfect tool to ensure that the cement manufacturing process is able to optimize its total output. Depending on the needs, Sintrol has the right solutions for each step of particulate measurement

Sintrol Product Line Solutions

Filter Leak Detection
In each area of the process where there are single or multiple compartment baghouses, Sintrol Snifter Series 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 Sintrol Snifters are largely maintenance free devices that can measure dust levels as low as 0.1 mg/m3. This device also has an ATEX 22 version available.

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. The Sintrol S303 monitor is equipped with a 4–20 mA output and all the features necessary to provide the end user with a continuous output. With high temperature versions (up to 700°C) available, this is a solution for all areas of the plant with dust measurement needs. The Sintrol S303 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), our Sintrol E-Spy is the industry’s only probe based monitor allowing the end user to get a continuous trend measurement in 4–20 mA output after an ESP. The customer can learn about the efficiency of its ESP, optimize the hammering process, and make adjustments to maximize the efficiency of the filter system utilizing the Sintrol E-Spy.

Monitoring For each stack in the plant, Sintrol’s S304 and S305 monitors can be calibrated to provide readings in mg/m3 for actual emissions amounts. Sintrol’s S305 monitor is a TÜV certified instrument, meeting the QAL1 standards for official emissions measurements in the European Union. These virtually maintenance free monitors are a less expensive and more reliable alternative to the traditional opacity monitors that have been used historically.

Case Studies