Cost reduction through optimised air and gas flows in cement production: Dirk Schmidt, Promecon, (Germany)

Filmed at Cemtech Asia 2015, 21-24 June, Grand Hyatt, Bangkok, Thailand


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So the content of the presentation is first of all who is Promecon, then I will speak a little bit about the product for the cement industry. We have developed the measurement method which is unique in this industry, and it was underlined during the last couple of conferences, where I have presented this technology that this is something really new. So, let's see.

The advantages and control application, for this technology I will give small light on. I will talk about optimization of Vertical Roller Mills, the fan control, the benefits, Klim ID fan control and also Clinker Cooler control. Last but not least it should be said that this Mass Flow Control is one outstanding opportunity also, to measure the gas flow going through Waste Heat Recovery boilers.

This is always a very crucial question, if somebody buy such a boiler who decide what is it efficiency later, okay? So, other process and applications and case study complete this presentation also a conclusion. So Promecan, who is Promecon? 1995 founded, sitting in Barleben close to Berlin in Germany. Our objectives and development and supply of sensors and controlled systems for the industry's power generation, cement and metal industries. And the products I want to take you a view on today are a drift free measurement hot and dust-lane airflow and gas stream.

Something that is not possible with delta P measurement. The McOn temp which is the wear resistant fast temperature measurement should be something maybe for the next conference. So, let's speak about a new development of measuring gas flows. Tribal electricity, sounds fancy is not so very new, it's developed and founded by wholesome companies 40 years back and we've brought it to a sufficient measurement system.

Anybody of you knows well that if you're a business youths, you sometimes have dust on that what is the result of that because that's electrical charged. This function is used usually in electric precipitators to take this dust out of the gas stream, we make the opposite. If you see a radio and compare a radio from the past you'll maybe remember that there is an antenna used, and an antenna is nothing else than a metal stick. In difference to radio waves which radio antenna receives we're using electric charged particles for this antennas. So, what you see is low direction is gas or air duct and in this gas or air duct are of course dust particles and they fly here along this antenna and the result is that you see that we can measure an electrical current. If you do so you'll agree that on a sensor you'll have a you see here sensor one a specific frequency pattern. This frequency pattern can compare when you use two sensors in a line of such a duct and very surprising one duct clot which is moving from sensor one to sensor two can be seen again. How can it be seen again? Mathematical wise something like this is called correlation, cross correlation and we use this cross correlation and processor unit and we find back when this clout reach sensor two. And what we do we measure the time in between so that what you see here is the most modern dust particle speed trap which we know also from the car driving when we get some nice photos.

How to use that compared to delta P? A big advantage is first of all that this speed measurement, doesn't need inventory, a pressure drop and this has of course a couple of advantages. From the beginning it has the advantage that you don't have to design and build during a new plant, design the inventory at all, seconds during operation you don't hear a pressure drop which is electricity consumption.

So, compare to delta P you don't have the necessity

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