7/30/2019 CS012Ben Cement Cooler Screen

1/2

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Clinker cooler

Level control with capacitance probe and monitoring electronic

High temperature probe Separate located

electronic unit

Discharge bins of

clinker fines

Nivotester

FTC625

Features

Process temperatures up to 400 C

(752 F)

Display and electronics can be mounted

separately

Extra data transmission safety due to

2-wire technology

Advantages

Maintenance reduced to a minimum due

to no moving parts

Preventive maintenance possible with

digital communication between transmit-

ter on FXA gateway as an option

Optimised process availability due to

remote access of process failure signals via

FXA gateway

Simple mounting and no calibration

means lower installation costs

The Challenge

In cement production, the clinker burning

process with the cyclone preheater, the

kiln and the clinker cooler, is the heart of

the process. The design and the process

technology selected along with the relevant

process automation have an important

influence in cement quality. The speed of

cooling influences the clinker properties

considerably:

with quicker cooling the crystal structure

will be finer and the required energy in

the grinding process reduced

rapid cooling in the high temperature

zone will reduce the water demand of the

finished cement

A clear detection and control of material

flow as well as the air volume in the clinker

cooler is therefore necessary to secure the

requested product quality standards. For

these reasons, reliable and robust sensors to

monitor the clinker cooler are required.

High temperature

probe T12656Fieldgate

FXA520

7/30/2019 CS012Ben Cement Cooler Screen

2/2

Instruments International

Endress+Hauser GmbH+Co. KG

Instruments International

P.O. Box 2222

79574 Weil am Rhein

Germany

Tel. +49 7621 975 02

Fax +49 7621 975 345

http://www.endress.com

info@ii.endress.com

CS 012B/11/en/01.05

55001834

IMPR/INDD 2.0

The Solution

At each clinker fines discharge outlet air

is blown into the cooler at the required

volume to bring down the temperature.

The air flow volume is individually adjusted

to optimize the clinker cooling process.

Uncontrolled build-up of clinker fines in the

discharge outlets will considerably affect

this cooling air flow and cause mechanicaldamage to cooler grates. To safeguard the

grate system each fines discharge outlet is

equipped with a capacitance high tempera-

ture point level probe. This level informa-

tion will control the double pendulum flap

at the discharge and maintain constant

conditions in the discharge outlet with

correct air flow.

Due to high temperatures the electronic

unit is installed separate to the probe. High

temerature capacitance point level probesare designed for a max. process tempera-

ture of 400 C (752 F) and equipped with

a special sword shaped probe end. This

sword option has a wide surface area to

give large changes in capacitance (good sig-

nals) while presenting only a small resistive

surface to the discharging material.

As the Clinker cooler area is seen as a cri-

tical process, it is necessary that all sensors

offer self testing and safe failure functionali-

ty and signal transmission. This data integri-

ty is attained using digital communications

with the EC27 smart electronic insert and

the Nivotester FTC625 electronic unit . The

Nivotester is specially designed for reliableand safe level detection based on two-

wire technology. Sensor failures and cable

breakages are also detected; in this case the

Nivotester FTC625, depending on the set

Fail to Safe mode, will activate or deactivate

the level output relay and activates the

separate alarm relay on the unit.

Benefits

The signals of the Nivotester FTC625 are

transmitted independent of the process

control system using a Fieldgate FXA520

gateway via a HART-Protocol and

Ethernet or GSM direct to the maintenance

department. Remote monitoring of process

critical limit values with alarm signalling

makes it possible to react directly to anychanges on-site. The data transfer in XML

format allows simple analysis and proces-

sing of the measured data. Condition moni-

toring and predictive maintenance is made

possible with the Endress+Hauser suite of

programming tools featuring ToF-Tool and

FieldCare.

Being able to monitor process measurement

trends and spot automation failures quickly

allows proactive maintenance which avoids

costly shut downs and improves inventory

management.

Reduced operational costs in the coolerprocess can be achieved whilst maintaining

and even improving required quality and

safety standards.

Further improvements in operational safety

are possible by comparing the level data

with other measurement data from the

control system.High temperature capacitance probe with separatelocated electronic unit

Transmitter Nivotester FTC625