FLUE GAS MEASUREMENT
PROBE HELPS CONTROL EMISSIONS
Konrad Doering, HeidelbergCement and Martin Liebau, ENOTEC, explain how a special probe with automatic cleaning ensures reliable flue gas measurement in a cement rotary kiln
investment in the company's history to date, amounting to more than EUR 100 million. The aim of this modernisation, which included the purchase of a heat exchanger kiln, was to reduce emissions, continuously increase the proportion of alternative fuels, and ensure consistently excellent product quality. A prerequisite for the realisation of these goals is data from the continuous and precise determination of flue gas emissions from the new cement rotary kiln. Since the inlet chamber between the rotary
F
kiln and the cyclone preheater is one of the most demanding measurement locations in any cement plant, HeidelbergCement decided to use the reliable rotary kiln inlet probe CEMTEC from ENOTEC. This measuring system for gas analysis was developed for the extreme operating conditions in cement plants and, thanks to a patented rotating device and automatic cleaning, enables permanent measurement of the gases directly in the rotary kiln - and thus permanent, accurate determination of the
rom 2016 to 2018, HeidelbergCement modernised its plant in Burglengenfeld with the largest single planned
necessary parameters. The conversion project at the plant was
carried out during the operation of the existing kiln lines and included a new 5-stage heat exchanger tower with calciner, a shortened rotary kiln, two new grinding plants for limestone with reduced specific power consumption, and a new fabric filter with a separation efficiency of almost 100 percent. The results of this modernisation were the reduction of emissions including the safe compliance with all limit values, an increase in energy efficiency, the reduction of CO2 emissions due to the improved efficiency, as well as a consistent product quality. The intended increase in the secondary fuel
feed and the additional calciner made the permanently available measurement data of a kiln inlet probe such as the model from ENOTEC indispensable, as the flour and fuel feed, the fuel mix and the air supply are influenced on the basis of its measurement data. The O2, NOx and CO content are recorded and controlled in detail, which, among other things, allows the clinker quality to be kept permanently high. "If you have a clear picture of what is happening at the kiln
The aim of the modernisation was to significantly reduce emissions, continuously
increase the proportion of alternative fuels, and continue to ensure excellent product quality Source: HeidelbergCement AG
inlet chamber, you can establish a very good correlation with other process parameters and quickly draw conclusions and make improvements," said Valentin Hamar, head of the kiln and shift operation at HeidelbergCement. The CEMTEC probe used to determine the
required parameters essentially consists of the water-cooled sampling probe itself, a compressed air tank, a recooler for the cooling water, the control cabinet for the cooling, the on-site control cabinet and a control cabinet with built-in PLC control. The ENOTEC probe can carry out all the movements required for continuous mass operation fully automatically - from retracting and extending, rotating by ±45° and tapping to pulse cleaning. All movements are implemented via compressed air, so that a single supply method ensures the safe operation of the probe. In the event of a failure of compressed air or power supply, a 1000l compressed air tank forms a sufficient reserve to ensure the safe extension of the CEMTEC. In addition, in the event of a power failure, a battery- operated UPS system in the control cabinet ensures that the probe moves into a safe
Thanks to a patented rotating device and automatic cleaning, the probe enables permanent measurement of
the gases directly in the rotary kiln - and thus permanent, accurate determination of the necessary parameters Source: ENOTEC GmbH
50 MAY 2021 | PROCESS & CONTROL
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