Process Gas Analysis

FLSmidth offers strong and powerful equipment specifically designed for pyro processing within the cement and minerals industries. Minimum of probe blocking incidents and easiest and fastest full-length probe maintenance when blocked (Less than 3 min.)

  • Overview

FLSmidth Process Gas Analysis systems

  • Optimise production throughput and quality
  • Minimise process operating cost and emissions
  • Easiest and fastest full-length probe maintenance when blocked (less than 3 min.)
  • Highest probe run factor due to high-powered air cannon-like cleaning (Patented One Pipe design)
  • Strong construction and simplicity of operation give long expected probe lifetime

Process gas analysis 

The process gas analysis program is primarily used to optimise pyro processes, thus reducing fuel consumption and optimising production throughput. However, the equipment is also necessary to avoid process conditions which could potentially lead to production downtime and increased demand for maintenance. Further, the equipment can provide early indication of production quality issues and unwanted concentration of harmful volatiles. If process expert systems such as ECS/ProcessExpert are used for pyro control, process gas analysis equipment is necessary to provide fundamental data for the system.

ROI: Depending on the type of production and pyro process, payback time for process analysis equipment is less than 200 days.

Typical components measured: O2, CO, CH4, CO2, NO, SO2 (Others on request)

Built for the most difficult processes

Process conditions in the cement and minerals industries can be very harsh. Temperatures can reach up to 1400°C, and dust loads can be as high as 500-2000 g/m3. Strong and powerful equipment is required to operate in this kind of environment. Handling the temperature and dust load, however, is a well-defined engineering task which can be solved. The real challenge is the process implications and the possibility of gas condensing in the raw material. Condensing of gas in raw material may happen if, even for a short period, high concentrations of e.g. volatiles occur in the process.

The result will be a sticky scaling on any surface exposed to the hot volatile-loaded gas. The engineering task to solve this problem is very complex, and no two pyro processes will be alike. The only two things which have proven to be certain in applying gas analysis to the cement and minerals industries are that there will from time to time be periods with unstable conditions and that during these periods any brand of probe will eventually get blocked. The question therefore is not if, but when a probe gets blocked by scaling, how do you handle it?

FLSmidth KilnLoq Probe - Simple and powerful design

There are different solutions to the task available on the market. FLSmidth, however, is certain that the large sales success of the FLSmidth KilnLoq probe is due to its simple and powerful design. Customers recognise the maintenance benefits of not having complex mechanical solutions involved such as e.g. mechanical plungers or rotating probes.

FLSmidth probes are based on simple, strong and reliable designs. In the high temperature KilnLoq probe this can be seen in the air cannon-like One Pipe (Patented) layout of the probe. The One Pipe layout provides unmatched probe cleaning power, without any obstacle to prevent maximum cleaning effect. As it is a straight pipe, there are no material deposits or cleaning power loss in filter, pipes or bends: this allows the KilnLoq probe to be as powerful as an air cannon.

The additional benefit of this design is seen when process conditions cause the probe to block. Due to the One Pipe design, a full probe-length cleanout can be carried out in less than 2 minutes. This capability will get the probe up and running again faster than any other probe system on the market. It will also provide data to the operators in order to correct an unstable condition sooner than would otherwise be possible. Powerful air cannon-like probe cleaning keeps the number of probe blocking incidents at a minimum and allows constant supervision by monitoring the pressure in the probe during analysis.

An additional feature of the KilnLoq system is its capability to monitor potential scaling tendencies in the process and on the probe. This feature will support proactive measures by maintenance staff and operators and help keeping the process and probe system running without unnecessary production cuts.


FLSmidth KilnLoq® HW Laser System – Kiln Inlet Gas Analysis

  • Combines two proven technologies, the KilnLoq® probe and Rosemount’s CT5100 laser analyser, to create the only laser-based hot/wet kiln inlet gas analyser on the market
  • Measures different gases (such as CO, NO, SO2, CO2 and O2) at the kiln inlet, providing the insights necessary to optimise fuel consumption and clinker quality
  • Laser technology for instant response time and precise readings
  • All parts heated to 180 ̊C, preventing condensation of sulphuric acid
  • Reliable gas analysis in high sulphur environments without the risk of acid damage

Accurate gas analysis with combined hot/wet process and laser technology

The KilnLoq® HW Laser System is a dependable and low-maintenance gas analysis solution that stands up to the high acidity challenges presented by the use of alternative fuels, such as tyres, by heating all parts to 180 ̊C. This high temperature is well above the dew point of sulphuric acid, preventing acid and eliminating the need to repair acid damaged gas analysis equipment.

With more than 300 references worldwide, the KilnLoq® probe is already known and trusted in the cement industry. The probe uses a unique One Pipe system, which samples gas in a straight pipe, providing many benefits for cleaning, maintenance and inspection.

The low-maintenance Rosemount CT5100 laser analyser used in the KilnLoq® HW Laser System has proven dependability, longevity and instant response time, along with a straightforward design and high degree of flexibility. It can measure up to 12 parameters simultaneously, increasing efficiency, and allowing easy on-site replacement of the laser modules for minimum downtime.

In addition to allowing for operational optimisations and meeting the challenge of gas analysis in plants with high sulphur levels, the KilnLoq® HW Laser System is also an ideal solution for plants that

  • want to measure water-soluble components such as HCl and H2O;
  • experience high SO3 values and want to measure SO2;
  • want to avoid H2O2 dosing due to safety and maintenance issues.


Cement Kiln Inlet GasAnalysis-KilnLoq

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Gas Analysis in Iron and Steel Production

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KilnLoq HW Laser System


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