Simplicity lies at the core of our approach to design... Why?
Complex solutions are prone to break down – and they can be tricky to service in a hurry.
Simple equals reliable and easy to fix.
The KilnLoq probe has a steel cooling jacket so it can resist the high temperatures in cement plants. Cold water circulates in the jacket to keep the probe cool – conventional technology that is safe, easy and cheap to maintain or replace. The central pipe where the gas is sampled, and the filter housing, are electrically heated to 180°C, so water or acid cannot condense. The KilnLoq’s cold water cooling system means its probe is 20 percent stronger than probes that use hot water or oil cooling systems. The KilnLoq probe can also estimate the amount of residue building up in the kiln inlet. Before the build-up can become large enough to cause a blockage or interfere with sample collection, the system sends a message to maintenance. This results in efficient kiln cleaning, less downtime and better analysis.
The probe has its own cleaning system to remove the residue that builds up during analysis. Three integrated cleaning devices work in harmony, making sure the probe can do its job even under the most extreme conditions. During cleaning, specially designed, fast-responding solenoid valves control the high pressure jets of air that blast deposits out of the One-Pipe probe and back into the body of the kiln. Installed in the extraction device, the valves are arranged for short hose runs and powerful cleaning throughout the length of the pipe.
Extraction Device (#2):
The kiln inlet can be a dangerous place, especially under off-set kiln conditions. But gas analysis equipment is essential under off-set kiln conditions, so continuous, safe operation is crucial. That is why we install the KilnLoq probe in an extraction device. During off-set conditions, when pressure in the kiln is high, anybody standing too close to any opening in the process potentially can be hit by a jet of super-heated dust. The extraction device allows the probe to be operated from a safe distance so there is no risk of exposure. To make operations safer still, you can opt for a probe process shutter. If the kiln operation is out of balance, material can build up around the probe. Under routine operation, most of these deposits are easily removed by the probe’s back-and-forth movements. The quick cleaning procedure – and the optional air-blaster operation – are sufficient to remove the rest. A power failure or weak flow of cooling water triggers the extraction device’s pneumatic piston, extracting the probe before it gets too hot.
Utility Air Supply (#5):
The Utility Air Supply guarantees the operation of the Extraction Device during e.g. a power failure period. Enough air is preserved in the air receiver to ensure a safe recovery of the probe in the event that compressed air supply is not available. The Utility Air Supply also provides enough air at the required pressure level during probe cleaning.
Water Cooling (#3):
The probe’s closed-loop water circuit is controlled by the probe cooling panel. Because the probe operates best when it is cold, the cooling panel operates at a high cooling capacity without any regulation of flow or temperature by default. If the cold water supply to the cooling system fails, the extraction device responds by retracting the probe from the kiln, so there is no risk of damaging the probe.
Gas Conditioning (#4):
Process gas generated by a cement kiln is very aggressive and corrosive. That is why FLSmidth’s extractive gas conditioning system has been developed for maximum safety. Not only have all the components in the gas conditioning system been through extensive testing, they have also proven their reliability and durability in action. Designed with simplicity in mind, the components are easy to service and maintain. And it comes with either a peroxide dosing system, or an optional super-chiller gas to keep maintenance to a minimum. The gas conditioning system is integrated into the GASloq cabinet.
The Control Panel allows the operator to Communicate with the KilnLoq system. A color touch screen gives the operator access to a large range of functions, including alarms, event lists and trend curves. A large symbol on the screen gives your maintenance people a one-glance summary of the equipment’s status. The control panel comes integrated into GASloq cabinet or as a field cabinet. Communication to the control room is available as hardwire or as an optional serial connections standards, such as Modbus, Profibus, Ethernet TCP/IP, and they are all supported by a fibre-optic uplink.