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Controlling Secondary Fuels and Aggressive Gases with Sick’s Gas Sampling System

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Sick offers a range of sensor solutions for diverse industrial applications. Tour Stop No. 35 takes a look at Sick’s hot gas sampling system for kiln inlets.  

The use of secondary fuels in the cement industry is increasing all over the world. Until now the cement industry depended on homogenous fuels such as gas, heavy fuel oil or coal.  

Conventional fuels are now increasingly being replaced by fuels produced from waste, which has led to difficulties in process management caused by the greatly varying composition of the fuels and aggressive gases.  

This has had an impact on gas measurement. Higher concentration of chloride and sulphur in the gas circuit at the kiln inlet causes a rise in the acid dew point in the analysed gas. Consequently the demand in measuring gas conditioning becomes more important.  

Lafarge Cement Cantalago, Brazil had no success in using a wet probe and its analyser system for controlling waste burn as well as coating formation at the smoke chamber, riser duct or kiln inlet.  

Sick offered an analysis system that reliably measured at the rotary kiln inlet.  

A successful combination at kiln inlet: MCS HW and SCP3000  

With Sick’s gas sampling system for kiln inlets, it is possible to analyse SO2 and other gases with minimum interference from the waste burning, according to the dimension, type and position of the probe in the rotary kiln.  

The hot measuring technology from Sick at the kiln inlet delivered optimal performance in the challenging task of measuring aggressive gases by combining the IR photometer MCS HW and the cement probe SCP3000, which was tailored specifically to the needs of the cement industry.  

This system allows reliable and robust kiln inlet measurement. The hot gas from the rotary kiln passes into the actual gas analyser via a heated filter, a heated sample gas line and a heated sample gas pump without any further gas preparation.  

The sample gas is extracted, filtered, conveyed and analysed at temperatures that are constantly above 200°C, always above the acid dew point. Any corrosive gas components are therefore no longer able to condense and dirt particles are also unable to settle anywhere inside the analysis system.  

The hot gas analysis also makes it possible to analyse water-soluble gas components. By measuring SO2 and HCl using Sick’s kiln inlet measurement system, the caking at the kiln inlet can be determined and the HCl signal can be simultaneously used to control the chlorine bypass.  

Highly reliable process gas monitoring at rotary kiln inlet  

The kiln inlet measurement system from Sick ensures reliable measuring values, high availability and robust durability with low operation costs.  

SCP3000 Cement Probe Features

  • Made of high temperature-resistant steel offering high resistance to bending
  • Relatively low quantity of dust will pass into the probe due to the extraction opening located on the probe’s tip that prevents direct entry
  • Dust filter and gas sampling probe can be cleaned regularly with compressed air ‘Shock Blower’
  • No caking of dust as a rotary device rotates the probe periodically by ±45° thus shaking off any accumulated dust and preventing caking at the probe flange
  • In the event of a fault, the probe is pulled back automatically to protect it from damage
MCS HW IR Photometer Features
  • Non-dispersive process photometer with the capability to analyse up to six IR active gas components
  • Can also measure oxygen as an option
  • Stable measuring ranges, which can extend from ppm range up to high volume %


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