Given the extreme conditions inside a cement kiln, monitoring the status of the refractory is vital. Detecting hotspots on the kiln shell is a proven way of doing so, as any refractory damage will show up as areas of overheating. While standard solutions rely on infrared (IR) scanners, our innovative Scanex®-IC system uses thermal digital cameras, with pyrometers for shadow compensation and state-of-the-art software, to provide high-resolution hotspot detection and better understanding of coating formation inside the kiln. The system can also include tire slip monitoring for additional insight into kiln shell conditions.
Combining thermal monitoring with state-of-the-art control and visualization software, the pyro experts at KHD have taken temperature monitoring to the next level with Scanex®-IC.
Measure the temperature of areas smaller than a refractory brick
Thermal imaging offers much higher resolution – and therefore greater degrees of accuracy – than traditional IR scanning. A range of optical systems are also available to support variable distances and camera view angles, enhancing the flexibility of the Scanex®-IC system and ensuring there is no loss of resolution at any point along the kiln (another weakness of IR scanners).
The result is more precise temperature monitoring. In fact, the temperature profile is measured down to an area less than the size of a refractory brick: much smaller than any hotspot you are likely to face. So, you can be sure of never missing a problem. You can also better track the performance of your refractory and understand any trends in hotspot formation.
Standard short kilns require one (two at maximum) cameras to provide full coverage of the length of the kiln. More cameras may be required for longer kilns; Scanex®-IC is able to merge inputs from up to four
This may sound complicated, but it basically means Scanex®-IC can ‘see’ through obstacles to generate a complete image of the kiln’s surface. It does this by seamlessly integrating the measurements of up to eight pyrometers into the thermal visualization.
Visualizing the kiln
Measuring is only the first part of the story. The Scanex®-IC software features an intuitive user interface, providing a highly-accurate visualization of the kiln surface temperature in real time. It also includes trending and alerts operators to fully-customizable alarm conditions, while data archiving allows the review of historical kiln conditions and is accessible remotely.
In addition, you are able to individually configure and visualize refractory zones by dimension, physical properties and installation date. The visualization software is installed on a separate industrial PC, which is included in the supply, or can be installed on a virtual system, when preferred.
Monitoring tire slip
In addition to the thermal imagery, when tire slip measurement is included, the user interface allows operators to set and measure parameters and receive alarm notifications for each kiln tire being monitored (up to a maximum of five).
A step forward in kiln temperature monitoring, Scanex®-IC offers high-resolution hotspot detection and better understanding of coating formation inside the kiln in a dependable, low-maintenance, easy-to-install solution.
Always available, always reliable
Traditional IR scanners – including our own earlier kiln monitoring systems – contain moving parts. Which is a problem in the sort of dusty environment found at most cement plants: scanners would require regular maintenance and might go down unexpectedly, if the moving parts seized. Realizing the challenge, we designed Scanex®-IC with (you may have guessed already!) no moving parts.
Meanwhile, the camera housing has been specially designed to withstand the harsh environment of a cement plant, and comes with a pressurized air connection for purging. To further ensure 24/7 availability of the system, a heating element or cooling system (also using pressurized air) can be included where ambient conditions require it, i.e., in very cold or very warm environments.
Simple, flexible installation
With the cameras pre-wired, Scanex®-IC comes in a ready-to-go package; you just need to provide power and a pressurized air supply. We also support you through the complete lifecycle of the product, from preparation and delivery, through installation and commissioning, and troubleshooting and maintenance.
There is also greater flexibility to how the cameras are mounted and where they can be positioned compared to previous kiln-scanning solutions. For example, they can be mounted above the kiln, looking down, if space limitations demand it.
Don’t just monitor your kiln, protect it
Issues with your refractory can quickly result in damage to the kiln shell, stopping production. To prevent this, you not only need to monitor the kiln shell temperature; you need to proactively tackle any hotspots. Again, the Scanex®-IC is here to help.
The system can connect with up to 16 kiln axial fans, which it will automatically activate when a certain temperature limit is reached. The Scanex®-IC software is also able to adjust fan activity according to fully customizable presets. This significantly reduces the likelihood of kiln shell damage. And means you can worry less about your kiln.