Waelz Rotary Kilns

Online Monitoring of the Waelz Process in Zinc Recycling

Optimize your recycling process in rotary kilns with state-of-the-art infrared measurement technology. Where conventional CCTV cameras fail due to extreme dust loads, our system provides a clear view of the material and precise temperature monitoring in real time.

Why Infrared Monitoring for the Waelz Process?

The Waelz process takes place at extreme temperatures of approx. 1,200 °C (2,192 °F). Without visual control, operators risk expensive downtime and efficiency losses:

• Prevention of Clinker/Lump Formation: Excessively high temperatures lead to material sticking (agglomeration), which drastically reduces zinc recovery rates.
• Protection Against Kiln Stoppages: Early detection of slagging at the kiln discharge prevents flow blockages and costly, time-consuming cleaning work.
• Optimal Process Control: By monitoring material temperature, parameters can be transferred directly to the Distributed Control System (DCS).

Our Turnkey Complete System

We supply not just a camera, but a complete industrial solution specifically developed for the harsh environment of zinc recovery:

• High-Resolution Infrared Furnace Camera: The PYROINC 640LF offers excellent image quality with 640×480 pixels – even through dense dust.
• Maximum System Safety: Equipped with an automatic retraction device that immediately removes the probe from the danger zone in the event of cooling or power failure.
• Integrated Control Cabinet: Central control and supply unit for continuous monitoring of all media (purge air, cooling water, power).
• High-Performance Evaluation Unit: Includes specialized software for visualization, alarming, and data transfer (4-20mA, Ethernet, or fiber optics).

All-Round Service from a Single Source

To ensure your plant performs at its peak from day one, we accompany you through the entire process:

1. Installation: Professional assembly and integration into your existing infrastructure.
2. Commissioning: Precise calibration and adjustment of parameters to your specific kiln conditions.
3. Training: Comprehensive instruction for your personnel to ensure safe operation and efficient data analysis.

Would you like to increase the efficiency of your zinc recycling? Contact us for a consultation or a detailed system demonstration.

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