K1

Infrared imaging and control for the Cement Industry

KILNSCAN 17KILNSCAN 17

KILNSCAN 17KILNSCAN 17

K2

Line ScannerLine Scanner

for for

Rotary Kiln Shell Temperature MonitoringRotary Kiln Shell Temperature Monitoring

KILNSCAN 17KILNSCAN 17Schematic installation layoutSchematic installation layout

K3

KILNSCAN 17KILNSCAN 17Two scanner configuration for elimination of shadow (merged images)Two scanner configuration for elimination of shadow (merged images)

K4

KILNSCAN 21KILNSCAN 21Example of site layout where 2 scanners are required (merged images)Example of site layout where 2 scanners are required (merged images)

K5

KILNSCAN 17KILNSCAN 17Two scanner configuration for long kilns (merged images)Two scanner configuration for long kilns (merged images)

K6

KILNSCAN 17KILNSCAN 17

K7

Ø

α

Diaphragm and multi right angle optic path for minimised effect of undesired radiation

Tiny sensitive area detector for extremely fine spatial resolution

Aspheric optics with focal length/optics diameter ratio less than 1 for high thermal sensitivity

Internal reference blackbody for calibration

Incoming radiation

Heavy duty brushless motor

Power supply

Aspherical lens

Amplifier digitization card + fibre optic emission card

Fibre optic cable

KILNSCAN 17KILNSCAN 17PERFORMANCESPERFORMANCES

KILNSCAN 17KILNSCAN 17PERFORMANCESPERFORMANCES

SCANNING RATESCANNING ANGLEINFRARED DETECTOR

THERMAL RANGETHERMAL RESOLUTION

SPATIAL RESOLUTION

: 20 Hz: 90° (optional : 140°): PbSe,

thermoelectrically cooled: 75 to 600°C: 1.5°C at 100°C

0.1°C at 600°C

: 2.0 mrad at 50 % of modulation: 5.0 mrad at 90 % of modulation

ACCURACY ( °C ) : ± 2°C

MAXIMUM LENGTH FOR FIBRE OPTIC : 1500 m

FOR A KILN LENGTH OF 60 METRES- Spot detection size : 60cm- Spot measurement size : 150 cm

NOMINAL LENGTH FOR FIBRE OPTIC : 100m

K8

KILNSCAN 17KILNSCAN 17PROCESS CONTROL SYSTEMPROCESS CONTROL SYSTEM

5 A complete installation includes :

1 - KILNSCAN 17 optical sensor.

2 - Connection by fibre optic.

3 - Data acquisition and processing.

4 - Kiln rotation contact switch.

5 - Blackbody/Pyrometer

K9

KILNSCAN 17KILNSCAN 17

- Kiln shell temperature monitoring- Refractory brick supervision- Coating thickness- Thermal warp

BENEFITS

- HOLDERBANK: Argentina, Chile, Italy, France, Switzerland.

- ITALCEMENTI / CIMENT FRANCAIS:Italy, France, Morocco, Turkey, USA.- LAFARGE : Austria, Chile, Germany, France, Morocco, Slovenia,Turkey, Venezuela.

- Others in Belgium, Brazil, China, Iran, Kenya, Luxembourg, Mozambique, Pakistan, Qatar.

MAIN REFERENCES

TOTAL NUMBER: 320 (Sept 2007)

K10

KILNSCAN 17KILNSCAN 17BENEFITSBENEFITS

Continuous monitoringof the kiln shell

temperature

Improved checking ofmechanical and thermal stress(thermal warp)

Supervision of burningzone

Display of burner adjustment effect

Display changesin thermal profile

Avoid unplanned stoppages

Increased shell,tyre and gear lifetime

Optimizationof kiln operation

Checking of burner adjustment

Extended refractorylining life

Conservation of the optimum thermal profile

K11

KILNSCAN 17KILNSCAN 17BENEFITSBENEFITS

Refractory supervision

Detects normal wear

Detects extreme wear in a limited zone

Detects a single fallen brick

Coating supervision

Conservation of optimum coating thickness

Detection, as soon asit happens,

of ring formation or coating changes

Forecast of Maintenance stoppage

Avoids unplanned stoppage

Increased refractory life

Avoids unplanned stoppage

K12

KILNSCAN 17KILNSCAN 17

K13

IP 65 enclosure

Dimensions : 215 x 225 x 70 mm

Weight : 5.2 kg

90° FOV 140° FOV

SCANNER HEAD

KILNSCAN 17KILNSCAN 17Positioning housing boxPositioning housing box

K14

KILNSCAN 17KILNSCAN 17Electronic receiverElectronic receiver

K15

KILNSCAN 17KILNSCAN 17Examples of cabinsExamples of cabins

K16

KILNSCAN 17KILNSCAN 17SOFTWARESOFTWARE

Real time functions :- Maximum, average, minimum thermal envelope profiling.- Thermal image synchronised with kiln rotation.- Temperature reference profile for entire kiln length.- Zoom image and zoom profile.- Manual selection of two pre-programmed temperature scales.- Up to 20 alarms thresholds with display of each.- Time tracking for temperature zones with intervals defined by end user.

- Personalized kiln parameters according to brick quality, tyre positione..

- Thermal warp calculation of non-symmetrical distortion of kiln shell.

- Histograms, analysis of historical data.- X and Y thermal profiles, coating and brick thickness, polar view.- Zoom image or zoom profile.- Statistical calculations.- Tyre slip monitoring,- Atmospheric absorption correction- Refractory management- 3 D thermal imaging.

K17

KILNSCAN 17KILNSCAN 173D display3D display

K18

KILNSCAN 17KILNSCAN 17Kiln shell temperature displayKiln shell temperature display

K19

KILNSCAN 17KILNSCAN 17Temperature profiles/ brick and coating thicknessesTemperature profiles/ brick and coating thicknesses

K20

KILNSCAN 17KILNSCAN 173D view, full kiln length3D view, full kiln length

K21

KILNSCAN 17KILNSCAN 17LinearizationLinearization

K22

KILNSCAN 17KILNSCAN 17Histogram (temperature distribution percentage over a preHistogram (temperature distribution percentage over a pre--selected area)selected area)

K23

KILNSCAN 17KILNSCAN 17Tyre slip monitoring Tyre slip monitoring

K24

KILNSCAN 17KILNSCAN 17Brick management Brick management

K25

KILNSCAN 17KILNSCAN 17Brick management Brick management

K26

KILNSCAN 17KILNSCAN 17Brick management Brick management

K27

KILNSCAN 17 KILNSCAN 17 Brick management Brick management

K28

KILNSCAN 17KILNSCAN 17Thermal warp Thermal warp

K29

KILNSCAN 17KILNSCAN 17Thermal warp Thermal warp

1 - Prior to problem

2 - During problem : (higher shell temperature due to change of burner adjustment)

3 - After problem : (re- adjustment of burner and change of silica index)

K30