THE

BENEFITS OF
IMAGING PYROMETRY
FOR THE CEMENT INDUSTRY
Claude Lorenson, Ph. D.
helpful in acquiring a sufficient picture in the dark environ-
ment of a clinker cooler. The signal from both the camera
and the infrared (IR) detectors are transmitted on a video
cable to a processor typically located in the control room.
The sensor head also includes all the electronics for the
pyrometer positioning and signal conditioning. A micropro-
cessor in the head acquires the raw data from the pyrometer
and transmits the information to the processor across a
video cable.
Figure 1. The sensor head of the Spyrometer splits the image
of the process into two parts. One portion of the image goes
to a CCTV camera for monitoring, and the other is presented
to an infrared detector for temperature measurement.
Inside the processor the video signals are digitized and
graphic elements (like cursors that define the measurement
zones and the temperature displays) are overlaid. The
resulting image is viewed on a VGA monitor. The quality of
the image obtained by the Spyrometer is excellent and good
definition can be obtained. The user is able to see both the
texture of the clinker and get a clear picture of the burning
zone inside the kiln. Different video controls for the image
can be adjusted from the control room using a mouse pad
connected to the processor. This arrangement permits easy
fine tuning of the image according to each operators
preferences without having to touch the camera on the kiln.
Easily accessed menu options provide another interface.
There are also sixteen 4-20mA analog outputs. This
provides an interface to plant instrumentation and control
systems. The installation of a Spyrometer requires no more
effort or access than a normal video camera.
II-B. Pyrometer
The pyrometer is mounted on an x-y translation table so
that it can scan anywhere in the field of view of the
camera. Two photodiode detectors are used with spectral
region narrowly centered at 0.8 micron (Silicon detector)
and 1.6 (Germanium detector) micron. This arrangement
permits the temperature measurement technique to be
either a two wavelength ratio or selectable single wave-
length pyrometer. The x-y translation stage is necessary
to have the detector scan the 32 measurement zones
defined by the user on the monitor screen. The ability to
directly view where the pyrometer is pointing is a major
advantage of this technique as one of the problems of
typical pyrometers is the difficulty in knowing exactly
which region is being measured. Also sometimes unusual
high levels of dust in a kiln will hinder the measurement.
I. INTRODUCTION
The Spyrometer

camera is an instrument that combines

enhanced video imaging capabilities with flexible infrared
pyrometry features. This kind of instrument provides many
monitoring and measurement features which makes it ideal
for utilization in the cement industry.
The rotary kiln in a cement plant is the single largest capital
investment, and making sure that operating conditions are
optimal in the kiln has a major impact on both the operating
costs and the quality of the product. There are many
specific areas where the Spyrometer can help in control of
cost and quality. The purpose of this application brief is to
highlight these areas and also to describe the characteristics
of the instrument.
II. PRINCIPLES OF IMAGING PYROMETRY
II-A. Lens Tube, Camera and Processor
Imaging pyrometry is the combination of video imaging and
a computer-driven pyrometer that measures the tempera-
tures of certain zones (selected by the operator) within the
image viewed on the monitor screen. To obtain an image
with good detail, it is necessary to place the optical objective
of the camera close to the process. The Spyrometers
objective is housed in a lens tube that is cooled and permits
insertion into the cooler. The objective is covered by a
sapphire window providing maximum protection from the
environment. The objective forms a broad image which is
transmitted through a series of transfer lenses to the camera
and the scanning pyrometer (see Figure 1). Lens tubes with
different fields of view and different optical paths are avail-
able. It is possible to position the camera in the kiln hood to
see both the burning zone and the clinker being formed. For
a clinker cooler installation the camera location depends on
if the flow of material needs to be seen, or if the temperature
and the clinker texture needs to be monitored.
Inside the instrument head, the optical signal is divided in
two using a beamsplitter. One portion goes to a CCTV video
camera and the other is transmitted to a scanning pyrom-
eter. The camera is sensitive in the near infrared which is
Positioning
Pyro Amplifiers
Co unications
A/D Conversion
Objective
Tr sfer Lens
Beamsplitter
Optical
Filter
X-Y Translation Stage
Infrared Detector
Video
Cable
Optical Path
to Process Mirror
CCTV Camera Control Electronics
With a typical pyrometer the operator has no way to be
sure of the measurement conditions. In the case of a
clinker discharge into the cooler, we often have seen
2
the
pyrometer pointing at the wrong region of the material flow
and therefore not giving the highest temperature in the
material. This is easily taken care of with the Spyrometer
because the measurement zone is chosen by the operator
from what is seen on the screen. It is also possible to
note unusual high levels of dust that would make the
temperature measurement suspect. This can greatly
increase the operators level of confidence in the pyrom-
eter.
There are 32 temperature measurement zones (TMZ) that
can be overlaid on the video image (see figure 2). These
zones can be moved anywhere within the image, therefore
giving the operator exact information on the measurement
spot. The size of the zone can also be changed.
Figure 2.
The emissivity value for each zone can be changed
individually (through the processor keypad) which insures
accurate temperature information when more than one
type of material is being monitored. The displayed
temperature for each TMZ can be set to represent the
average, minimum or maximum temperature in the zone.
The Spyrometer provides maximum flexibility in its
temperature measurement capabilities which can be used
for:
Burning zone monitoring
Material temperature during clinkerization
Monitoring of clinker cooler performance
Coating diagnostic
These will be discussed in the next section.
The ability to chose the method of measurement (one
wavelength or ratio two wavelength pyrometer) is the key
to the Spyrometers flexibility. A two-color pyrometer
measures two different wavelengths emitted by the target
under observation. By comparing the two signals and
computing the ratio at the output of the detectors, the two-
color method
3
can eliminate many of the problems
associated with single color pyrometry. The main problem
afflicting the cement kiln would be: dust that obscures the
line of sight and emissivity changes on some of the
material under observation. The emissivity changes can
be due to temperature or change in surface conditions.
For example, when dust obscures the line of sight, there is
a loss of signal in a single wavelength pyrometer but in a
two-color ratio instrument, as long as the effect of the dust
on the output signal is the same at both wavelengths, the
output ratio is the same as if the target was not obstructed.
The temperature depends on the ratio so there is no
temperature error associated with the measurement due to
the dust obscuring the line of sight. In a similar manner, if
the emissivity of the material changes, but is the same at
both wavelengths, there is no temperature error associ-
ated with the change in emissivity.
The Spyrometer temperature measurement technique is
based on two detectors (as opposed to a single detector
with a filter wheel or temperature inferred from video
level) which guarantees fast output response time. The
nature of the detectors makes the instrument virtually drift
free. The algorithm that computes the temperature from
the output voltages of the detectors is accurate to within 1
K for the temperature range of the instrument. The
temperature accuracy is 1.0% full scale.
In the next section we will see how the instrument can
help in specific areas of concern in a cement plant.
III. SPECIFIC BENEFITS FOR CEMENT KILN
III-A. Fuel Cost
The cost of fuel is one of the major expenses in the
making of cement. To insure the most efficient use of
fuel, there are many variables to monitor inside the kiln.
Among the variables that can be monitored using the
Spyrometer are:
Burning zone temperature
Material temperature
Length, shape and direction of the flame
In the past, some of this was done by the operator looking
through a port in the kiln but more recently, cameras have
helped this process of monitoring the flame. The
Spyrometer provides a color image of the process which
facilitates the acceptance of the instrument to the operator
in many cases.
Temperature information is most often provided by several
different pyrometers, sometimes pointing at the wrong part
of the process. This can be corrected when combined
with the visual information when a Spyrometer is mounted
on the kiln hood. The fact that there are 32 TMZ's can also
help in monitoring the burning zone and its effect on the
feed materials. Having the ability to position several
measurement points gets rid of the limitation of traditional
kiln set-up where one or two spot pyrometers are used.
For example, it is possible to locate several TMZ's along
the material path (beyond the burning zone in some cases
where contrast permits) and in this way gain feed tempera-
ture information which can alert to a change in the charac-
ter of the feed bed (see figure 3). Changes that occur in
the calcining zone usually cannot be seen by the operator
4
since they take place behind the burning zone. With the
Spyrometer camera, changes in the character of the feed
can be observed. These changes influence the level of
CO
2
in the exit gases which is critical in fuel efficiency.
This can sometimes provide early warning of possible
changes in burnability and help reduce the number of kiln
upsets.
Another parameter that affects the fuel efficiency/cost is
the flame itself
4
. The Spyrometer provides the perfect
combination to not only view the flame but also more
importantly to monitor its effect on the feed. In general,
the best conditions are obtained with the shortest possible
fire and the highest possible flame temperature without
affecting the clinker quality, the coating formation or the
refractory life. The temperature of these three items can
be monitored with the Spyrometer and therefore help in
tuning flame characteristics. Close attention on the
overall burning zone is necessary to produce the correct
heat flux to the product. Too low a heat flux produces a
high free lime (above ~1.5%) which is an important
parameter for product quality. Too high a heat flux pro-
duces overburned clinker with an excessive liquid phase
which is also detrimental to the quality of the final product.
The condition of high heat flux also results in excessive
temperature at the kiln discharge which can be harmful to
the life of the equipment in the discharge area. With the
Spyrometer it is possible to monitor the temperature of the
clinker right at the discharge.
The length and the direction of the flame can also be
monitored with the Spyrometer. In practice the length of
the flame is the parameter that is adjusted to change the
heat flux. An increase in excess air shortens the flame
and increases the heat flux to the feed. A change in
excess air of 15% changes the flame length by about 20
meters. The problem with too much excess air is the extra
heat carried to the preheating zone of the kiln which
translates in higher heat loss and therefore in greater fuel
consumption. There is a fine balance to maintain. Better
monitoring aids in obtaining the best overall operating
conditions for the flame and helps in the fuel efficiency.
The Spyrometer also gives a very good picture of the
plume (the non-ignited fuel). The length of this parameter
is influential on the efficiency of the burner.
Because the Spyrometer provides imaging pyrometry, it
also becomes very useful in adjusting the flame direction.
Since the best heat exchange between the flame and the
feed takes place when the flame is pointed somewhat
toward the feed, the effect on material temperature and
the coating can be monitored as the flames direction is
changed. With the ability to read the temperature
changes as the flames direction is changed, much quicker
feedback can be obtained therefore minimizing possible
upset conditions.
The flame temperature itself can be monitored in two
ways: observing the color changes or by placing a TMZ
on the flame and charting the temperature changes as the
burning conditions are modified. It is desirable under any
operating conditions to obtain the highest possible flame
temperature without affecting coating or clinker quality.
By monitoring it, it is possible to control it. A decrease in
the flame temperature can be a sign for adding more air,
reducing kiln speed or reducing fuel rate to improve
combustion. All these have obvious effect on fuel cost.
In the context of reducing fuel cost, the Spyrometer helps
the user with the control of:
Length of the flame and its effect on the overall heat
flux
Length of the plume which has an effect on efficiency
Flame direction and the heat transfer to the feed
material
When all these variables are optimized, fuel savings of up
to 5% have been reported
5
.
III-B. Waste Derived Fuel
The Spyrometer provides a tool that is versatile and can
help in all tasks necessary to produce operating conditions
of maximum efficiency. The output of up to 16 TMZ's can
be monitored on a continuous basis and used by a control
system via the 4-20 mA analog outputs. For kilns that
burn many different types of fuel (in some cases waste
derived fuels), the Spyrometer lets the operator see
changes in the flame and in the burning zone as fuel
combinations change. Different fuels can effectively
move the burning zone in the kiln. The ease in resetting
the TMZ on the Spyrometer is very useful in this situation.
These kind of kiln fuels are also often subject to strict
standards to control possible harmful emissions. For
example, the BIF (Boiler Industrial Furnaces) standards in
the US set minimum and maximum operational tempera-
tures for different waste derived fuels. In this situation two
TMZ's are used in the minimum and maximum displayed
temperature mode. The 4-20mA analog outputs on the
processor are used to alarm the control system when the
temperature is outside the correct range for a given fuel.
III-C. NOx Emissions
Figure 3 - The temperature measurement zones are placed along
the kiln to monitor the burn zone and its effect on the clinker.
In the context of NOx emissions, the flame temperature is
a critical parameter. Because of the high flame tempera-
ture which occurs in the kiln, the dominant source of NOx
is thermal NOx. One of the strategies to reduce NOx is to
reduce the fuel/air mixing which also reduces the flame
temperature and the heat flux to the feed
6
. The
Spyrometer is used in this case to monitor the tempera-
ture of the feed and help in deciding the proper fuel/air
mix to provide tighter control of emissions.
III-D. Refractory Life
Another aspect of cost where the Spyrometer can be
helpful is in the monitoring of the refractory. Hot spots can
easily be pinpointed with the maximum temperature
feature displayed. This will help to alert to possible early
failure of the refractory. The formation and loss of coating
depends directly on the temperature of the feed, the
coating already present, and the flame itself. The ability
to monitor temperature at more than one place can help in
making a diagnostic on a kiln that is too hot or too cold,
and to keep a good amount of coating on the shell. A good
coating can help prolong the life of the refractory thus
reducing costs.
III-E. Clinker Cooler Monitoring
The clinker cooler has to cool the clinker to a temperature
low enough that it can be transported to the storage area
and at the same time it must recover heat so that combus-
tion air can be provided to the burning process. There are
two locations where the Spyrometer has been successful
in helping to monitor the cooling process. One is in the
middle of the cooler tunnel and the other is on top of the
discharge. In the first case, a wide field of view lens
located at about mid-length of the cooler permits a clear
picture of the flow of material from the exit of the kiln to
the point where the material is sufficiently cooled. In this
kind of installation it is possible to see the river of reds
and other unacceptable types of cooling patterns existing
in the cooler. It is also possible to monitor the tempera-
ture of the clinker from discharge to about mid-length.
After that the temperature of the surface is too low to be
monitored by the Spyrometer. This is useful information in
optimizing cooler grate fan air rate. In the case of a
clinker cooler, the temperatures are taken as a guide
because of depth variations and different degrees of
cooling air that can be present in the field of view.
To monitor the texture and the temperature of the clinker
at the exit of the kiln, it is better to place the camera on
top of the cooler chute or at mid-height of the discharge.
If only the clinker needs to be seen, a narrower field of
view lenses can be used. In this way a good quality
picture of the clinker texture can be obtained. Having a
Spyrometer in this location helps monitor the pile-ups and
hot spots that can take place. It also provides a good
monitoring tool for looking at the level of excess dust.
Since this dust is reintroduced into the kiln as part of the
secondary air, it is possible to reduce the number of kiln
upsets if actions are taken when the dust level becomes
too high.
The benefits of using a Spyrometer in a clinker cooler are:
Monitoring temperature material through the cooler and
helping optimize cooler grate fan air rate
Inform the operator of unacceptable cooling patterns that
can damage equipment and compromise quality
Monitor the dust level and reduce kiln upsets
IV. SUMMARY
It is the combination of pyrometry with imaging that brings
new flexibility in instrumentation for the cement kiln. By
providing a two-color pyrometer that can be targeted on any
part of the image seen by the camera, it is possible to have
reliable temperature data even in the presence of dust.
Knowing where the pyrometer is pointing at all times gives
increased confidence in the temperature measurements. By
having 32 temperature measurement zones, a number of
monitoring and control functions can be performed. The
Spyrometer has proven helpful in the field to:
Reduce fuel costs
Reduce kiln upsets
Prolong the life of refractory
Provide a tool for tighter control of NOx emissions
Help in optimizing cooler performance
V. REFERENCES
1. K.Peray, J .Waddell, The Rotary Cement Kiln, Chemical
Publishing Company, 1972
2. Personal Communication
3. T.Harrison, Radiation Pyrometry and its underlying Principles
of Radiant Heat Transfer, J ohn Wiley & Sons, 1960
4. P.J . Mullinger, Fuel Cost Reduction by Flame Control, World
Cement, March 1986
5. Personal Communication
6. P.J . Mullinger, Cement Kiln Firing and Clear Air
Requirements, World Cement, December 1994
For more information, please contact Sales & Marketing at:
IST, Quadtek Products
19501 144th Ave NE, #F1100 Woodinville, WA 98072
USA Phone: (425) 881-0778 Fax: (425) 869-0667
e-mail: sales@quadtek.com Web:
www.istimaging.com
2004 by IST Printed in the United States All Rights Reserved SPYROMETER
is a registered trademark of IST QLN1298 RevC