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Cement Industry

Cement Industry

Cement manufacturing operates under extreme conditions with high temperatures, abrasive materials, and heavy dust loads. Reliable level and pressure instrumentation is essential for maintaining process efficiency and optimizing energy consumption across all production stages.

Overview

The cement industry operates under demanding conditions involving high temperatures, abrasive materials, and heavy dust loads throughout the production process. From raw material extraction and grinding through clinker burning to final product storage, reliable instrumentation is essential for maintaining process efficiency and product quality. Level measurement in raw meal silos, coal storage, and cement silos must withstand extreme conditions while delivering accurate readings. Pressure monitoring across kilns, preheaters, and grinding systems helps optimize energy consumption, which represents one of the largest operational costs in cement manufacturing.

Industry Challenges

Key challenges we help address

Managing extreme temperatures and dust in kiln environments

Preventing clinker silo blockages and bridging

Monitoring raw meal homogeneity for consistent product quality

Optimizing fuel consumption across alternative fuel sources

Reducing unplanned downtime in continuous production

Tracking emissions to meet environmental regulations

Use Cases

Explore specific scenarios and challenges in this industry

Blending bed

Blending bed

Cement Industry

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.

Cement silo

Cement silo

Cement Industry

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.

Clinker cooler

Clinker cooler

Cement Industry

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.

Clinker silo

Clinker silo

Cement Industry

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.

Compressor

Compressor

Cement Industry

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.

Conveyor belt

Conveyor belt

Cement Industry

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.

Conveyor belt transfer station

Conveyor belt transfer station

Cement Industry

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.

Crusher

Crusher

Cement Industry

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.

Cyclone

Cyclone

Cement Industry

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.

Mobile diesel tanks

Mobile diesel tanks

Cement Industry

Diesel is stored in tanks on construction sites to supply the construction vehicles with fuel directly on site. A sufficient supply of diesel fuel is essential for optimal construction site operation. Exact level measurement, in combination with wireless data transmission to a central location, ensures automatic, optimal provisioning of mobile containers at all times.

Raw meal silo

Raw meal silo

Cement Industry

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.

Silo for solid fuels

Silo for solid fuels

Cement Industry

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.

Stacker

Stacker

Cement Industry

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.

Tank for liquid fuels

Tank for liquid fuels

Cement Industry

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.

Truck loading

Cement Industry

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.

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