The innovative KilnLoq probe is the only gas analysis sample probe on the market capable of ensuring this - day after day, at a minimum of maintenance and with an unprecedented high run factor. With the short pay-back period regardless of kiln size, the KilnLoq probe becomes a compulsory application for any cement plant.

Benefits

Experience has shown that a kiln inlet gas analysis system will reduce the number of kiln stops caused by raw material blockings effectively. To illustrate the importance of this: a kiln producing e.g. 5000 ton clinker/day at a global average market price of 56$/ton clinker will loose approx. 11,650$/hour during a kiln stop on that account alone. A kiln inlet gas analysing system only has to reduce this number of stop hours by approx. 15-20 before the investment is returned which is achievable at most plant. On top of this, the benefits from the other areas of improvement will only add to the final result given.

The main objectives achieved by kiln inlet gas analysis are production stability, reduced production costs, optimised fuel consumption and reliable kiln operation. The benefits of analysing e.g. O₂ in the kiln inlet may be clarified in this way:

• An excess in oxygen level of 1% in the kiln inlet can be converted to a 2% higher clinker production
• An excess in oxygen level of 1% in the kiln inlet can be converted to a 1% lower fuel consumption
• A shortage in oxygen level of 1% in the kiln inlet will cause kiln stops, wear, excessive manual clean-outs

In order to exploit these benefits, the analyser must be on-line all the time providing consistent, comparable and accurate data of the kiln operation. To ensure this, FLSmidth Airloq has developed a patent pending gas sample probe named KilnLoq.


The KilnLoq principle

The idea of the KilnLoq probe is to be truly simple, strong and reliable as we have found these qualities to be the fundament for a high run factor of any probe system. To facilitate this, we have used the principle of an air cannon/shock blaster in our initial design of the Kilnloq probe. The outcome is the KilnLoq probe consisting of one big air tank, one valve and one straight pipe. This layout results in a probe being simple in operation, extremely powerful in cleaning and maintenance and very reliable - just like an air cannon! In order for a kiln inlet gas analysis system to be succesful in obtaining the production objectives, it needs to have a high run factor. The KilnLoq probe provides this through a unique and powerful design that alters the conventional way of performing extractive analysis.

The high run factor is founded on the probe being simple, strong and reliable.

Simple: The design is simple, making it uncomplicated to operate and keep in operation. Maintenance is easy, and the equipment utilises only conventional components for easy unsophisticated replacement.

Strong: The probe is made from a special high temperature alloy capable of long-term operation in the kiln inlet of a cement process. The mechanical strength is more than 8 times stronger than its predecessor. The layout of the probe like an air cannon provides the most powerful and effective cleaning seen in the market removing any obstacle inside the probe.

Reliable: Built-in know-how from our many years of experience in the specialist field of gas analysis in the cement kiln inlet provides proactive measures to a system with a market leading run factor. Unique detection systems for material build-up both inside and outside of the probe give less maintenance and longer periods between required service. The reliability of the system makes it a compulsory measurement for the kiln operators in order to optimise a stable clinker through-put. 

To learn more about our capabilities in calciner gas analysis and the KilnLoq probe – please go to the datasheet download area or contact a sales representative.