Infrared-Rotary Kiln-Temperature-Monitoring

Problem:

Temperature-Hot-Spots on the kiln-shell give informations about defects of the kiln brick lining. Low-temperature zones within the brick lining range of the sinter zone permit conclusions on beginning of caking inside the rotary cement kiln.

 

Tasks:

  • Recognition and visualization of Hot spots and beginning caking-rings
  • Integration of the measured values into a primary Control system

 

Solution:

  • Thermal kiln-shell monitoring on rotary kilns with infrared line camera

 

Components of the IR-OMT:

  • High efficient infrared line cameras for rough industrial environment
  • Robust housing with heating and cooling
  • Industrial control cabinet for the camera supply
  • PC system with integration into the customized control system
  • Software „IRT KilnMonitor “for the monitoring, evaluation and analysis

 

Kiln-Monitoring-Software

Features (choice):

Several kilns

Representation and processing up to 4 kilns per evaluation unit.

 

Bricks and coating thickness calculation

Bricks and coating thickness is estimated using the actual kiln shell temperatures and the kiln development history stored in the database.

 

Hot-Spot-Finder

If a Hotspot in the infrared image develops, this is put out in accordance with their coordinates at the kiln shell and as zoom shot picture. This Hotspot is then represented in a trend representation in dependence of the temperature rise. External blower fans could be place targeted and controled by the „IRT KilnMonitor-Software.

 

Worst case” image

Image that shows maximum temperature at every kiln shell spot over some selectable period of time.

 

Alarms

On-screen display, beeper, external hardware alarms and OPC alarms;

 

History

Kiln state (scanned infrared image, bricks and coating thickness, alarm state) is continuously recorded in a database.

 

Client-server model

Server is the computer collecting data from the scanners. Client is any computer in the local network (or as an option – in the Internet).

 

Rotary-slip-monitoring

 

Advantages:

  • Pyroelectric sensor with drift stability
  • Multi-camera solution also for in-house rotary kilns
  • During multi-camera solution no shadowing, no additional pyrometers necessarily
  • Line string with lens optics (maintenance-poor, high life span)
  • Optimized measuring line by the use of objectives, optimum tuning on the rotary kiln
  • Small absorption of H2O (water vapour or fog) in the measuring wavelength 8 – 14 µm
  • Network-able by fast ethernet interface

Freigabe1_kompr
Infrared-Linescanner in
weatherproof housing

 

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3D-false colour image

Schema1_01
Using infrared cameras to monitor
rotary kilns

 

Software3
3D image with brick lining

Software4
2D image of the rotary kiln

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Installation diagram