Infrared Insights

Temperature monitoring across the cement manufacturing process is essential to support process efficiency and cement product quality. It can also help to prolong the life of the kiln through early detection of refractory issues or insufficiently quenched clinker, which could lead to production stoppages if left unchecked. Monitoring solutions also support safety and emissions control.

For these reasons, non-contact infrared thermometers and thermal imaging systems play an important role in helping to protect valuable assets in a cement plant.

Importance of effective clinker cooling

Clinker cooling is a stage where hot clinker is rapidly cooled to temperatures that can be handled by downstream equipment. Efficient clinker cooling is a critical process in cement production, impacting not only the quality of the final product but also the safety and longevity of the production equipment. Rapid cooling is essential to ensure the clinker formation stops at the optimal point in the reaction. Effective operation is also needed to recoup a significant part of the thermal energy from the red hot clinker. Ineffective cooling can lead to several issues, including:

• Quality degradation: Improperly cooled clinker can result in poor cement quality.
• Equipment damage: Residual heat from improperly cooled clinker can cause damage to conveyor belts and other equipment.
• Fire hazards: Hot clinker fragments can ignite fires on conveyor belts, posing significant safety risks and potential operational shutdowns.

Given these risks, it is essential to employ reliable and precise cooling and monitoring systems. The integration of advanced infrared temperature measurement systems into clinker cooling processes offers significant benefits for monitoring, safety, and operational efficiency.

The role of infrared temperature measurement in clinker cooling

Infrared temperature measurement systems play a pivotal role in optimising the clinker cooling process. Some cement plants integrate single-point infrared thermometers within their system, but these measure the temperature in a small area near the centre of the conveyor and can miss small hot objects when looking at the whole width of a conveyor.

Linescanning technology offers several advantages here. For example, linescanner systems scan at high speeds and high resolutions, ensuring comprehensive coverage and detection of any anomalies, even very small uncooled clinker fragments. This level of precision is critical in preventing potential issues before they escalate.

When a hot spot is detected, the system can activate a high-speed alarm. This immediate response allows for prompt action to be taken, preventing potential fires and equipment damage.

The system should also provide continuous monitoring of the clinker cooling process, delivering the real-time data that is crucial for maintaining optimal cooling conditions and ensuring the quality and safety of the cement production process.

Implementing a linescanner-based monitoring system enhances the clinker cooling process in several ways:

• Preventing conveyor belt fires: By detecting small hot clinker fragments that are insufficiently cooled, the system prevents these fragments from causing fires on the conveyor belt. A high-speed alarm allows operators to intervene before any significant damage occurs.
• Ensuring equipment longevity: Continuous monitoring and precise detection of hot spots help protect conveyor belts and other downstream equipment from the detrimental effects of residual heat. This protection extends the lifespan of the equipment and reduces maintenance costs.
• Improving operational efficiency: Real-time data provided by the system enables operators to maintain optimal cooling conditions, ensuring that the clinker is adequately cooled before moving to the next stage of production. This efficiency translates to better overall operational performance and product quality.

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Read the article online at: https://www.worldcement.com/special-reports/30092024/infrared-insights/