of the overall costs are not uncommon within cement manufacturing. But there are ways to optimize the process.
Facing volatile commodity prices on the one side and complex customer demands on the other, the need for optimized processes within the cement industry has never been higher. Think for example of the energy costs in the clinker manufacturing process, which can represent up to 75% of the variable costs. But to efficiently lower your expenses without compromising the quality of your products, accurate process data derived from reliable instruments is key.
Whether you are managing a project, automating a fuel handling system, selecting instruments for your clinker process or packaging a NOx gas cleaning solution for your environmental compliance program, our experienced process automation consultants can handle all measurement and control requirements of fully-integrated cement plants:
Clinker burner measurement and control
Automation, storage and control systems for alternative fuels
Cyclone preheater blockage control instrumentation
Crusher and feeder optimization
Maintenance optimization with local support
Click through these maps to learn in detail how you can reduce your production costs
Clinker manufacturing is an energy intensive activity and choosing fuels, the right blend of hot gases and optimum burner control affects both the environmental impact and the economics of the process. Total energy cost can represent 65-75% of the variable costs in the process. For effective process control in the clinker production process, optimized measurement packages are essential.
Coriolis meters optimize the burner by regulating the mass flow of oil to the burner and provide the oil heating system with online temperature and viscosity measurements
Boiler and burner monitoring station with stand-alone optimization software
Boiler level and temperature instrumentation
Clinker burner flame pressure and temperature instrumentation
Flow meters for air cooling and high temperature radar level sensors for clinker bed height monitoring to regulate cooler grate speed and air volumes
Online clinker density and free-lime measurement
Non-intrusive blockage sensors for material collection silos under the clinker cooler grate
Non-invasive mass flow measurement sensor system for clinker screw or belt feeders
Temperature sensors and transmitters for tertiary gas pipes
Raw materials feed gas flow rate monitors
High-accuracy, thermal, shock-resistant sensors for cyclone chamber pressure control
Latest in high-tech, abrasion-proof alloy thermocouples with vibration-resistant electronics for long-life temperature monitoring
Non-invasive cyclone buildup and blockage detectors
E+H industry consultants have together with our customers achieved remarkable results and improved plant optimization whilst maintaining high levels of operational safety in many industry sectors like precious metals, cement and steel production. Apart from our technical expertise and the industry optimized product portfolio the basis for such success is our business creed. We believe in building long-lasting relations with customers and not just short term profits.
smart level sensors in cement silos worldwide
years of experience in measurement instrumentation
devices installed worldwide