Cement industry

Cement is one of the most important raw materials for the construction and expansion of infrastructure. The processes in cement production require a high level of productivity and efficiency. IPTech sensors measure reliably in all areas of this industry: from the quarry to the storage of cement.

Application

To maintain a high quality and uniform material consistency in the finished cement, the raw materials are homogenized in a blending bed. To achieve this the rock is distributed evenly over the blending bed with a stacker. Material is reclaimed in reverse order with the help of a scraper. In order to optimally control the conveyor systems, their positions must be determined as precisely as possible.

Your benefit

Reliable

Reliable measurement despite strong dust generation

Cost effective

Exact position monitoring without mechanical wear

User friendly

Maintenance and wear-free

Process data

Measuring task:

Level measurement

Measuring point:

Reflective surface

Measuring range up to:

120 m

Medium:

Reflective surface

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Dust, noise

Application

To attain high quality and uniform material consistency in the finished cement, the raw material is homogenized in a so-called blending bed. The rock is distributed evenly over the blending bed with a stacker. Material is removed with a scraper. To ensure that the incoming material is distributed as evenly as possible, the level must be continuously measured.

Your benefit

Reliable

Reliable measurement even with strong dust generation

Cost effective

Optimum storage capacity utilization

User friendly

Maintenance and wear-free

Process data

Measuring task:

Level measurement

Measuring point:

Stockpile

Measuring range up to:

30 m

Medium:

Rocks

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Dust, noise

Application

Before being burned in the rotary kiln, the material from the blending bed and the aggregates are ground to a fine raw meal in large mills. The powdery material is then transported to the silo by a pneumatic conveyor system. Reliable monitoring of the level is essential for optimal raw material storage.

Your benefit

Reliable

Reliable measurement ensures a continuous supply of raw material

Cost effective

Optimal stocks ensure continuous production

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

20 m

Medium:

Raw meal

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Strong dust generation, buildup

Application

To produce cement, the raw meal is burned to clinker in a long rotary kiln. After leaving the rotary kiln, the clinker has a temperature of up to +1300 °C and must be cooled down to a temperature of about +200 °C for further storage. To achieve this, the clinker bed is cooled with a continuous stream of air. Pressure monitoring is required in the lower part of the clinker cooler to make the cooling as effective as possible. The material height of the hot clinker, at over 1000 °C on the conveyor belt, also has to be reliably measured.

Your benefit

Reliable

Reliable monitoring of cooler process

Cost effective

Optimal cooling with minimum energy expenditure

User friendly

Maintenance-free measurement

Process data

Measuring task:

Level and pressure measurement

Measuring point:

Conveyor belt

Measuring range up to:

1 m

Medium:

Burned clinker

Process temperature:

0 … +1500 °C

Process pressure:

0 … +100 mbar

Special challenges:

High temperatures, dirt and buildup

Application

After the raw meal is burned, the emerging clinker of varying consistency is stored for further processing. The silos are filled and emptied through different openings. Continuous operation of the subsequent production processes is ensured by level measurement and point level detection.

Your benefit

Reliable

Reliable measurement despite high temperatures

Cost effective

Optimal stocks enable continuous production

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

30 m

Medium:

Clinker

Process temperature:

-40 … +200 °C

Process pressure:

0 … 0 bar

Special challenges:

Dust, abrasion, high temperatures

Application

The air compressor system generates the necessary compressed air to transport the material from the silos via the network of feed pipes. To ensure a smooth, steady flow of material, reliable pressure monitoring in the compressors and conveying channels is required.

Your benefit

Reliable

Safety shutdown in case of excessive pressure

Cost effective

Constant supply of compressed air for production

User friendly

Maintenance-free operation

Process data

Measuring task:

Pressure measurement

Measuring point:

Conveyance channels

Measuring range up to:

0 … 18 bar

Medium:

Air

Process temperature:

+5 … +30 °C

Process pressure:

0 … +18 bar

Special challenges:

Pressure shocks

Application

Before further processing, the cement is stored in tall silos. The cement is transported both in and out of the silo via pneumatic conveying. Efficient storage and transport of the product is ensured by accurate level measurement and point level detection, as well as also monitoring the pneumatic conveying system pressure.

Your benefit

Reliable

Reliable measurement ensures a continuous supply of raw material

Cost effective

Optimal stocks enable continuous production

User friendly

Maintenance-free operation

Process data

Measuring task:

Level and pressure measurement, point level detection

Measuring point:

Silo

Measuring range up to:

50 m

Medium:

Cement

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Strong dust generation, buildup

Application

In clinker production, cyclones are used to preheat the raw meal. Before the raw meal enters the rotary kiln it is preheated to +900 °C in the cyclone. Constant monitoring of the buildup thickness on the walls ensures a continuous process.

Your benefit

Reliable

Reliable buildup measurement despite high temperatures

Cost effective

Monitoring the formation of buildup ensures high availability of the cyclone

User friendly

Simple external mounting

Process data

Measuring task:

Buildup measurement

Measuring point:

Cyclone

Measuring range up to:

3 m

Medium:

Raw meal

Process temperature:

+300 … +900 °C

Process pressure:

0 … 0 bar

Special challenges:

Heavy deposits and buildup

Application

Large amounts of energy are needed to burn clinker in rotary kilns. Apart from conventional energy sources such as gas, oil and coal, solid substitute fuels such as dried sewage sludge, old tires or meat and bone meal are increasingly being used. Since the required amounts of energy represent a significant cost factor in cement production, exact level measurement of the solid fuels is essential.

Your benefit

Reliable

Reliable measurement ensures a continuous supply of fuel

Cost effective

Exact content measurement reduces logistics costs

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

20 m

Medium:

Coal, meat and bone meal, recycled materials

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Strong dust generation, deposits

Application

Large amounts of energy are needed to burn clinker in rotary kilns. Substitute liquid fuels such as spent oils or recovered solvents are often used for this purpose. The fuel storage tanks often contain a mixture of solvents, which can produce fumes and vapours in the air space. Due to the large amount of energy needed in cement production, the fuel inputs represent a significant cost factor, so accurate level measurement is essential.

Your benefit

Reliable

Reliable measurement under all operating conditions

Cost effective

Optimal storage

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Tank

Measuring range up to:

5 m

Medium:

Fuel oil, heavy oil

Process temperature:

-10 … +80 °C

Process pressure:

0 … 0 bar

Special challenges:

Media with low dielectric constant

Application

The large boulders are extracted from the solid bedrock with blasting. This very first stage in the process is needed to enable these very large rocks to be crushed by smaller, secondary jaw and roller crushers, which create the smaller sizes for screening to produce the basic building materials like gravel, grit or sand. To enable efficient, continuous operation and keep wear on the crusher as low as possible, level measurement and point level detection are required.

Your benefit

Reliable

Reliable measurement ensured even in noisy environments

Cost effective

Uninterrupted operation thanks to optimal process feed

User friendly

Simple installation and setup

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Crusher

Measuring range up to:

5 m

Medium:

Stones

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Strong noise and dust generation, extreme abrasion

Application

The transport of coarse and fine bulk solids within a stone processing facility takes place in most cases via conveyor belts. To achieve an even throughput and compensate for volume fluctuations during transport, belt transfer points are integrated in the conveyor line. The incoming bulk material is briefly stored in a buffer silo to prevent belt overfilling. This is the point where the level and the point level must be monitored.

Your benefit

Reliable

Reliable monitoring of silo filling

Cost effective

Optimal utilization of conveyor belt capacity

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

5 m

Medium:

Stones, gravel and sand

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Extremely noisy and dusty environment, abrasion

Application

Bulk aggregates are fed into production processes via conveyor belts or screw conveyors. For effective feed control to and from these processes, or inter-production unit billing, the mass flow of the conveyed bulk material must be measured. A reliable belt-weighing scale system and mass flow rate ensures accurate measurement and smooth operation of the plant.

Your benefit

Reliable

Reliable measurement despite changing belt tension and vibrations

Cost effective

Optimal mass flow measurement allows exact accounting of bulk solids

User friendly

Maintenance-free operation

Process data

Measuring task:

Throughput measurement

Measuring point:

Conveyor belt

Measuring range up to:

10,000 t/h

Medium:

Bulk solids

Process temperature:

-40 … +60 °C

Process pressure:

0 … 0 bar

Special challenges:

Vibrations, dirt, changing material size

Application

Dust-free, closed loading systems are needed for fine aggregates and finished products such as cement. Automated loading of trucks is preferred in the industry and, while the load quantity is determined with a weighing system, it must be ensured that the truck is in the correct place and not overfilled. Reliable point level detection and vehicle positioning shortens loading times, increases throughput and improves the efficiency of the entire system.

Your benefit

Reliable

Reliable measurement under tough operating conditions

Cost effective

Optimal filling of silo vehicles

User friendly

Simple setup and commissioning

Process data

Measuring task:

Point level detection

Measuring point:

Silo truck

Measuring range up to:

Gravel, grit and cement

Medium:

Stones

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Harsh environment, extreme dust generation

Application

Accurate measurement of tank content is an essential part of liquids logistics planning, especially when it comes to maintaining a sufficient supply of fuel for the vehicle fleet. Precise level measurement is required in order to ensure optimal stocking.

Your benefit

Reliable

Maximum confidence in measurement

Cost effective

Optimum fuel stocks for the vehicle fleet

User friendly

Simple installation and commissioning

Process data

Measuring task:

Level measurement

Measuring point:

Tank

Measuring range up to:

10 m

Medium:

Diesel

Process temperature:

-20 … +60 °C

Process pressure:

0 … 0 bar

Special challenges:

Changes in density due to temperature fluctuations

Cement industry

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