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Cement Production

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Seeing through the fire

Infrared camera systems in cement production

Reliable furnace monitoring with high-temperature-resistant camera systems – for greater safety, efficiency, and process control.

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Zement

Infrared furnace cameras in the cement production

Water-cooled furnace cameras, featuring integrated IR cameras and specialised furnace lenses, enable continuous optical monitoring of processes within furnaces to the highest standard.

Revolutionize Your Cement Production with INSPECT pro Control C and Our Technology Partner ci-tec

Maximum Efficiency through Intelligent Infrared Control and Alternative Fuels.

In the modern cement industry, reducing energy costs and CO₂ emissions is critical for competitiveness. With INSPECT pro Control C, we offer a globally unique, patented solution to safely and efficiently control the use of Solid Recovered Fuels (SRF).

Why INSPECT pro Control C?

  • Precision through Infrared Technology: Our camera-based monitoring enables the exact measurement of clinker temperature and fuel trajectory directly within the rotary kiln.
  • Optimized Combustion Process: By continuously adjusting burner parameters, we achieve stable production and prevent incomplete combustion.
  • Significant Cost Savings: Replace fossil fuels with more cost-effective alternatives. Save through the use of SRF – often achieving a Return on Investment (ROI) of less than one year.
  • Sustainability Focus: Reduce your ecological footprint through massive CO₂ savings, supported by state-of-the-art analysis software.

Our Technology at a Glance:

  • Real-Time Analysis: Infrared camera system with specialized IR analysis software.
  • Seamless Integration: Visualization directly in the control room and provision of all parameters to your Distributed Control System (DCS).
  • Tailor-Made: Customizable to your specific requirements and kiln types.

Transition now to the cement production of the future. Contact us for a detailed feasibility and cost-benefit analysis for your site.

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Klinkerkühler

Infrared furnace cameras on the clinker cooler

Water-cooled, optimised infrared furnace cameras with special combustion chamber lenses enable continuous optical monitoring of processes with temperature measurement in the clinker cooler to the highest standard.

Optimization of Clinker Cooling through Infrared Measurement Technology

As part of an IGF research project, an innovative method for increasing energy efficiency in rotary cement kiln plants was developed. By using optimized (narrow-band) infrared cameras, it is now possible to precisely monitor and specifically optimize clinker cooling.

The Process: Intelligent Condition Monitoring

The heart of the process is the installation of a PYROINC IR camera at a strategically favorable, low-dust position within the cooler area. This camera continuously provides high-resolution thermal images of the clinker bed, enabling detailed "condition detection."

Based on this real-time data, temperature gradients are derived, which serve as the foundation for an automated control loop. By specifically adjusting control variables – such as the stroke lengths of individual planks in walking floor coolers – the temperature profile of the clinker bed can be actively leveled and homogenized.

Positive Results and Advantages

Operational tests conducted during the project demonstrate the enormous potential of this technology:

  • Significant Energy Savings: Through improved heat recovery, a significant reduction in specific thermal heat consumption was achieved. Notable fuel savings were realized in the test series.
  • Improved Heat Recovery: The optimization led to an increase in secondary air temperature and a more efficient utilization of clinker heat (achieving up to a 1/3 increase in heat recovery).
  • Consistent Product Quality: Extensive examinations (including microscopy and XRF analysis) confirmed that the optimized cooling has no negative impact on clinker properties.
  • Process Stability: The visualization of temperature trends in the control room supports personnel in continuous cooler optimization and ensures more stable kiln operation.
Conclusion

The use of specially optimized PYROINC IR cameras for controlling clinker cooling is a decisive step toward more resource-efficient cement production. The process offers a field-proven solution to reduce operating costs while minimizing environmental impact through reduced fuel consumption.

Arrange a personal consultation

Would you like to learn more about CMV Systems products or find out which device is best suited for your application? Please feel free to contact us!

+49 (2165) 87915-0   info@cmv-systems.de