FLSmidth Airloq's new completely redesigned kiln inlet analysis probe was released for sales on January 1st 2004 after a very successful and trouble-free test period. June 18th 2007, number 100 probe had been sold. With 100 probes sold and 3 years site experience, the patent pending probe has fully lived up to FLSmidth Airloq's high expectations.
FLSmidth Airloq A/S has developed and tested a new probe for measurement of flue gas from kiln inlets at cement plants on the basis of onsite experience. The KilnLoq gas analysis system is especially designed for the high temperatures and dust loads in cement production. Typical applications are kiln inlets, riser ducts, calciners and cyclone exits.
About the probe
The new probe is simple and provides easy maintenance. It is strong and prevents bending of probes. It is reliable and ensures trouble-free operation and dependable analysis results for the operating staff. The new KilnLoq probe has turned the design of gas analysis probes upside down.
Consequently, FLSmidth Airloq has applied for a patent for the idea, which is built around one pipe through the entire probe which may be cleaned without disassembling the probe. The probe itself is significantly thicker than the previous version, and a special steel type has been used to improve the probe's strength. A PLC (Programmable Logic Controller) monitors and ensures the system's reliability with a proactive control system, which for instance initiates an automatic purging already at initial clogging.
Onsite experiences
The probe has been installed and tested since July 2003 at kiln 87 at Aalborg Portland where coal and various forms of waste are used as fuel. The new KilnLoq system has now replaced the old probe at kiln 87.
Only a few changes to the design and control system have been made in the intervening period. During the same period, 100 KilnLoq probes have been sold all over the world to plants in Finland, Spain, Chile, Jamaica, Australia, Canada, USA, the United Arab Emirates, India, Thailand and several other countries.
Our conclusions from the test installation as well as site experiences have been as follows:
- An extremely high operating ratio has been achieved
- The probes have very rarely been disassembled for maintenance
- Preventive maintenance has taken less than 30 minutes per week in average
- The probe has proven simple and easy to maintain
- The investment in a KilnLoq gas analysis system has shown to be very favourable with a pay-back time of less than 200 days
Case story
Ain Touta cement plant in Algeria has had problems with their gas analysis system since 1986. In the period from 1986 to 1991, a huge amount of time was spent on daily maintenance caused by probe blocking, leakage, problems with the jet pump, water circuit, manual extraction, etc.
From 1991, the system was completely out of service, until the cement plant purchased a new KilnLoq system from FLSmidth Airloq. The KilnLoq was commissioned in May 2006.
Recently, FLSmidth Airloq conducted a satisfaction survey in which Belkhiri Mokhtar, the head electrical engineer. On behalf of the plant's operational staff, he expressed his full satisfaction with the KilnLoq system's performance, simplicity and especially easy maintenance.
"I would like to congratulate all FLSmidth Airloq staff for designing the successful kiln inlet analyser, the Kilnloq", Mr Mokhtar states. He explains that the operators at Ain Touta only perform one or two visual inspections of the probe and analyser system a week. According to Belkhiri Mokhtar, the system works perfectly. Since the commissioning, the probe has never been blocked, and the run factor has been almost 100% as the system is only stopped for a short time during probe filter cleaning or calibration.
The case story from Algeria is in no way unique as it represent the typical responses received from customers equipped with the new KilnLoq probe system.
For further information on the KilnLoq system, please contact Area Sales Manager Christian Markussen at chma@flsairloq.com or tel. +45 96 68 20 10.