Process imaging in cement!

Raytek has introduced the CS210 process imaging system for cement kilns. This fully integrated kiln shell scanning system enables cement manufacturers to continuously monitor rotary kilns to detect hot spots due to refractory loss, damage and wear, and as a result, avoid costly damage and unscheduled downtime.

Using the CS210 infrared (IR) linescanning solution, cement plant operators can determine the effectiveness of kiln refractory material. Any fallen bricks will be quickly detected and appropriate action may be taken to prevent further damage. Scheduled maintenance can also be planned to replace the refractory with a minimum of downtime. Thus, the refractory life can be extended to provide economic benefits, and emergencies can be averted.

With the CS210, temperature is monitored along the entire length of the kiln shell with "one brick" resolution. The system provides fail-safe hot spot alarm outputs. Operators can also detect abnormal conditions, such as faulty flame position and shape. Temperature data for areas "shadowed" from the main sensor are provided by individual point sensors and seamlessly integrated into a complete, real-time thermal image.

At the core of the CS210 system is a specially built MP150 HR linescanner with 1024 data points per scan line, and an integral heater, configured for the user's kiln applications. Featuring state-of-the-art optics, advanced microprocessor electronics and a high-reliability motor, the MP150 combines signal processing, data storage and data communications into one integral unit. To insure reliable operation in even the harshest kiln environments, the linescanner is designed with a rugged cast aluminum housing, which, in turn, is mounted in a stainless steel protective housing with provisions for air-purge and water-cooling.

The CS210 process imaging system employs onboard Ethernet TCP/IP communications and interfaces with other programs via OPC. The system's user-friendly DataTemp® CS Software is fully compatible with Windows® 7 and provides easy configuration/startup, as well as multiple security settings. The graphical user interface is designed specifically for kiln applications, allowing for easy scanner set-up and use with little operator training.

Installation of the CS210 process imaging system has been greatly simplified with the addition of a single fiber-optic communication channel to carry all system data from the scanning system located at the kiln to the host computer imaging system in the control room.

With DataTemp software accessories, the CS210 system expands to become a comprehensive kiln monitoring tool. For example, optional burning zone sensor and Live Ring Migration (LRM)-tire slip monitoring can be integrated into the system so that complete information is displayed on a single screen in the control room, and all data, events and alarms are stored and accessible in a common database. Fan control and shadow monitoring accessories are also available.