Sensors applied in cement industry

In the cement industry, various types of sensors are applied for different purposes. Cement temperature sensors, typically thermocouples, are used for monitoring purposes within the cement manufacturing process. Additionally, Level, pressure, flow sensors are employed to easy-to-measure online process variables. These sensors play a crucial role in ensuring optimal operations and quality control in the cement industry.

Cement Manufacture

Cement manufacture is a complex process that involves the mixing of raw materials, grinding, and heating to high temperatures in a kiln to produce clinker. To ensure optimal operations and quality control, various types of sensors are employed in the building construction cement industry.

Typical application scenarios

Level and pressure measurement in the clinker cooler

To produce cement, the raw meal is burned to clinker in a long rotary kiln. After leaving the rotary kiln, the clinker has a temperature of up to +1300 °C and must be cooled down to a temperature of about +200 °C for further storage. To achieve this, the clinker bed is cooled with a continuous stream of air. Pressure monitoring is required in the lower part of the clinker cooler to make the cooling as effective as possible. The material height of the hot clinker, at over 1000 °C on the conveyor belt, also has to be reliably measured.

Level measurement of the blending bed

To attain high quality and uniform material consistency in the finished cement, the raw material is homogenized in a so-called blending bed. The rock is distributed evenly over the blending bed with a stacker. Material is removed with a scraper. To ensure that the incoming material is distributed as evenly as possible, the level must be continuously measured.

Level measurement and point level detection in rock crushers

The large boulders are extracted from the solid bedrock with blasting. This very first stage in the process is needed to enable these very large rocks to be crushed by smaller, secondary jaw and roller crushers, which create the smaller sizes for screening to produce the basic building materials like gravel, grit or sand. To enable efficient, continuous operation and keep wear on the crusher as low as possible, level measurement and point level detection are required.

Sensors for Cement Manufacturing

Features

In the cement manufacturing industry, various types of temperature, pressure and level sensors are employed for monitoring and quality control purposes. These sensors are used to gather data and provide real-time information on parameters, enabling effective quality control and process optimization.

Benefits

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SPR400 Series Rotary Paddle Level Switch

SRL602 26G High Frequency Horn type Radar Type Level Transmitter

PM450C Wireless pressure transducer with dual temperature measurement

Cement storage

Proper storage of cement is crucial for maintaining its quality and ensuring its fitness for use in construction projects. By following these guidelines, construction professionals can ensure that cement is stored properly, preserving its quality and ensuring optimal performance in construction projects.

Typical application scenarios

Level, pressure, flow measurement and point level detection in cement silos

Before further processing, the cement is stored in tall silos. The cement is transported both in and out of the silo via pneumatic conveying. Efficient storage and transport of the product is ensured by accurate level measurement and point level detection, as well as also monitoring the pneumatic conveying system pressure and flow.

Detecting the position of the stacker in the blending bed

To maintain a high quality and uniform material consistency in the finished cement, the raw materials are homogenized in a blending bed. To achieve this the rock is distributed evenly over the blending bed with a stacker. Material is reclaimed in reverse order with the help of a scraper. In order to optimally control the conveyor systems, their positions must be determined as precisely as possible.

Level measurement and point level detection in raw meal silos

In bulk material measurements in cement plants, before being burned in the rotary kiln, the material from the blending bed and the aggregates are ground to a fine raw meal in large mills. The powdery material is then transported to the silo by a pneumatic conveyor system. Reliable monitoring of the level is essential for optimal raw material storage.

Level measurement and point level detection in tanks for liquid fuels

Large amounts of energy are needed to burn clinker in rotary kilns. Substitute liquid fuels such as spent oils or recovered solvents are often used for this purpose. The fuel storage tanks often contain a mixture of solvents, which can produce fumes and vapours in the air space. Due to the large amount of energy needed in cement production, the fuel inputs represent a significant cost factor, so accurate level measurement is essential.