SCANNER SYSTEM DESCRIPTION

TEMPERA is a shell temperature monitoring system

for rotary kilns. It uses a high-resolution infrared line
scanner, connected through electronic hardware to a
computer located in the control room (see figure 1).
The rotating movement of the kiln allows monitoring
the whole surface of the shell, thus obtaining a
complete scan with each turn.

F
igure N 1: Block Diagram

Radiation data provided by the line scanner is

converted to temperature values through
software, which takes into account the
atmospheric absorption effect and the thermal
emissivity of the kiln, as well as the
characteristics of the detector.
Temperature data is displayed in a computer
screen as thermal maps (thermograph).

The line-scanner detects the infrared radiation

emitted from a narrow area of the shell that
subtends an angle of 90 or 120 horizontally
(depending on the scanner being used). The
system generates more than 1000 data points
for scan. The scan takes only few milliseconds
and occurs 20 (40 or 80 optional) times per
second (see figure 2).

Figure N 2:

SCANNER TEMPERA
TEMPERATURE MONITORING SYSTEM FOR ROTATORY KILN

Infrared line scanner measurement

principle description

TECNOLOGA INTEGRAL S. A.
Soluciones Tecnolgicas Avanzadas
Empresa Certificada ISO 9001:2008

FUNCTIONAL CHARACTERISTICS
ON-LINE INFORMATION

Any unusual thermal behaviour on the kiln

shell will be quickly spotted by the operator
thanks to the information displayed onscreen, which will allow him to promptly
take the right corrective actions.

ANALYTICAL CAPABILITY

TEMPERA stores all the information automatically. This as

well as a series of functions loaded into the system, allow a
detailed analysis of the thermal conditions of the kiln. One
of these features is to schedule in advance the necessary
repairs of the kiln.
It being able to virtually "see" the refractory bricks wall
avoids expensive brick stocking because the state of the
internal refractory wall after a campaign is known before
opening the kiln.

HISTORY

The TEMPERA system automatically

stores information from the shells thermal
maps, as well as hourly averages,
maximum and minimum. This information
is employed, by using specific commands,
to show the recorded information on
screen, at different dates. Distinguishing
between different data allows evaluate and
optimise the operating conditions of the
kiln. It also helps in the detection of hot
spots, falling of refractory bricks, formation
of rings, etc.

SCANNER TEMPERA
TEMPERATURE MONITORING SYSTEM FOR ROTATORY KILN

TECNOLOGA INTEGRAL S. A.
Soluciones Tecnolgicas Avanzadas
Empresa Certificada ISO 9001:2008

REFRACTORY ADMINISTRATION

Displaying on-screen the type of refractory

wall being used in the kiln, gives the operator
access to information regarding changes
made, elapsed operation time, last measured
thickness, installation date, etc. These data,
plus the temperature information, allows
determining the condition in which the
refractory wall is, and facilitates decisions like
the campaigns extension, or the overall
dimension of necessary works in order to
properly maintain the kiln.

KILN POSITION ENCODER

In order to take advantage of the analytical options of the program, TEMPERA can
perform temperature measurements in synchronisation with the rotational movement of
the kiln by using a kiln position encoder module. With this set-up it is possible to correlate
the temperature measurement with the position of the shell kiln independently from the
fluctuation of the rotational velocity of the kiln.

TIRES

The system is capable of detecting slippage anomalies in each one of the tires. To
achieve it, TEMPERA measures and keeps updating on-screen, the slippage value in
millimetres, for each revolution of the kiln. Information is saved, being able to obtain hourly
averages and daily and monthly trends. Should a tyre displace out of range (preconfigured by the operator), then the alarm for that tire is triggered.

COOLING FANS AND ALARMS

TEMPERA permanently shows a graph of

extreme temperatures (maximum and
minimum) and simultaneously displays the
limits for the different zone or cooling fan
alarms. The tolerance level of each alarm
blinks if the value of the parameter being
used to monitor a given zone is out of its preset value (see Figure 3). The system allows
the configuration of up to 10 distinct alarms
for each kiln or 25 cooling fans, using
different areas or zones and setting the upper
and lower limits individually.

SCANNER TEMPERA
TEMPERATURE MONITORING SYSTEM FOR ROTATORY KILN

TECNOLOGA INTEGRAL S. A.
Soluciones Tecnolgicas Avanzadas
Empresa Certificada ISO 9001:2008

NETWORK THERMAL MONITORING

TEMPERA-NET has the ability to connect to

the computer network used in the plant, which
allows the real-time display of the kilns
monitoring process and perform thermal
condition analysis from any office inside or
outside the plant.

ADVANTAGES

Maintenance cost reduction

Operational costs reduction
Increase in productivity
Safe operation
Management capacity improvement
Historical analysis of the kiln

TEMPERA is a powerful tool for kiln thermal management, providing important information
that allow the safe operation of the kiln along the whole period of production, also the
efficiency optimisation of the production process, and the programmed maintenance of the
refractory wall reliably and at a minimum cost.
The time required to regain the initial investment varies strongly with the type of kiln and
the degree of control on the clinker production process. In most cases, the savings
generated by the longer lasting of the refractory wall, extended production campaigns
without not-programmed halts and optimised kiln operation, justify the employment of
TEMPERA since the first months of use.
Alexandre Chriguer
Application Engineer
ECIL Produtos LTDA - Piedade - SP
Tel. +55 15 3244.8052 | Cel.+55 15 9630.7096

e-mail: chriguer@ecil.com.br / Visite nosso site: http://www.ecil.com.br

SCANNER TEMPERA
TEMPERATURE MONITORING SYSTEM FOR ROTATORY KILN