Gas

Monitoring
Following on from Mark Yseboodt’s
article, ‘Safety First’, in the January 2006
issue of World Cement, Lothar Luckei,
Product Manager FLK Gas and John
Cobain, Siemens Process Instrumentation
and Analytics, describe some of the
challenges faced by cement plant operators
when implementing gas analysis systems.

Introduction
Increasing environmental regulation, the widespread
use of alternative fuels and the need to accurately
report and monitor mean that systems for gas analysis
are a key part of cement plant infrastructure. This
article describes some of the challenges faced by
cement plant operators, and how Siemens technology
contributes to the smooth operation of the process.

LDS 6 for NH3 slip measurements in

DeNOx plants
In the clinkering zone of a cement rotary kiln, the raw
meal is transformed into clinker at a temperature of
approximately 1400 °C, making flame temperatures of
up to 2000 °C necessary.
At these high temperatures and with the oxidising
conditions resulting from excess air, nitrogen oxides
(NOX) are produced in the kiln exhaust (thermal NO
production) with a share of approximately 95% nitro-
gen monoxide (NO) and 5% nitrogen dioxide (NO2).
A reduction in the production of NO is primarily
achieved by optimising kiln operation. This mainly
includes optimisation of the calcination process, the
dosing of fuel and raw materials, retrofitting of the
rotary kiln plant to precalcination technology, and the
use of modern furnace technology (low-NOX burners).
However, if such measures do not enable the plant
to adhere to prescribed limits (500 mg/m3 according to
EU 2000/76/EC), it is necessary to take secondary meas-
ures. There are two main techniques for reduction of
GAS ANALYSIS

NO levels: SCR (Selective Catalytic Reduction) and SNCR

(Selective Non-Catalytic Reduction).

The SCR process

In this process, the nitrogen oxides (NO) are decom-
posed into water (H2O) and nitrogen (N2) by addition
of a reducing agent such as ammonia (NH3) or urea
upstream of the catalyser. Depending on the dust load
and the type and concentration of acidic gas compo-
nents, the SCR process is operated in the temperature
range from 250 °C to 400 °C. The NH3 slip is very small

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 as a result of the high efficiency of the catalyser, and is
usually in the low ppm range. An increase in NH3 slip,
despite the process conditions remaining the same,
indicates a decrease in catalyser efficiency.

The SNCR process

In this process, the reduction of NOx is achieved by
adding ammonia in a temperature range from 800 °C
to 1050 °C. When using a rotary kiln with cyclone heat
exchanger, the optimum point for addition of the
reducing agent is in the rising shaft from the rotary kiln
to the heat exchanger.
If ammonia or urea is added below this temperature
Figure 1. LDS 6 laser spectrometer measurement points for NH3
window, the reduction of NOX becomes incomplete,
slip measurement.
and the NH3 slip (non-converted NH3 in the exhaust)
increases. On the other hand, should ammonia or urea
be added above this temperature window, NOX levels
actually increase, caused by the oxidation of NH3.
Parts of the non-converted NH3 are bound on the
raw meal and dust, and result in additional reactions.
The NH3, together with the acidic components of the
flue gas, can result in the production of salts that can
lead to major problems in the process sequence.

Figures 2 (above) and 3 (below). LDS 6 laser spectrometer design
and implementation.
Task description
NH3 slip is an important parameter for process monitor-
ing and optimisation in DeNOX plants, and must be
kept as low as possible.
The LDS 6 laser diode gas analyser is an in-situ
analyser for simultaneous determination of NH3 slip at
up to three measuring points. The real-time measure-
ment allows rapid control, and prevents over-dosing of
the reducing agent. One pair of sensors measures the
residual amount of NH3. The LDS 6 can be used for both
the SNCR and SCR procedures. Optimisation of a DeNOX
plant means:
l Reduction in consumption of ammonium or urea.
l Stabilisation of process, and avoidance of plant
faults.
l Reduction in the emission of NOX and NH3.
l Environmental protection.
l Monitoring catalyst efficiency.

The measuring principle of the LDS 6 is based on the

specific light absorption of different gas components.
The key features of the LDS6 are:
l Real-time and in-situ measurement under process
conditions.
l No cross-sensitivity.
l Dynamic compensation of dust load.
l Permanent valid calibration by using a reference
GAS ANALYSIS

cell.

Figure 4. LDS 6 laser spectrometer measurement points for
monitoring the ESP.
Design
The LDS6 consists of a compact analyser unit and up
to three in-situ transmitted light sensors, comprising
transmitter and receiver units. A hybrid cable with
glass-fibre and copper wires connects the analyser unit
to the sensors. The sensors are connected together by
a cable.
The internal reference cell ensures permanent and
automatic calibration validity of the analyser. Operation

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is extremely user-friendly and CO monitoring of
requires low maintenance. coal silos
The modular system design An increase in the CO
means that individual compo- levels provides a good
nents can be replaced on-site indication that a smoul-
should this become necessary. dering fire is contained
Fast CO monitoring within the silo, and
upstream of ESP necessitates immediate
Cement plants are frequently countermeasures, such
equipped with ESPs for filter- as warning of personnel
ing exhaust gases. The preven- or the purging of the
tion of explosive gas mixtures silo with protective gas.
is a pre-requisite to reliable As a result of the dan-
operation of the filter. A gas ger potential, fast and
mixture of approximately 12% reliable measurement
carbon monoxide (CO) and Figure 5. Integrated solutions for monitoring the coal silo. of the CO concentration
6% oxygen (O2) is considered is necessary under all
to be explosive. The ESP must conditions.
be shut down before these By measuring along
levels are reached. the optical path and
Reasons for the spontane- not extracting point-
ous production of CO usually like gas samples, a
include: faulty furnace control high representation
and the unsatisfactory com- of the measurement is
bustion of secondary fuels, ensured. This, together
e.g. old tyres. with the high measure-
As a result of the high ment speed, enables the
gas velocity of approximately real-time detection of
20 m/s upstream of the precip- smouldering fires and
itator and the long response therefore immediate
time of approximately 20 countermeasures to be
seconds for extractive gas taken.
sampling, the measuring
Figure 6. Siemens Sitrans LR 400 FMCW radar level monitor: ideal
point at the outlet of the for high-dust level measurement applications.
Solution
preheater is normally used for The LDS6 laser diode
CO monitoring. As a result of gas analyser provides
these deficiencies and in the interest of safety, the CO the best possible features for this application. A
limits for isolation of the ESP are usually not greater pair of sensors is installed directly on the silo walls,
than 2%. The frequent result is faulty deactivation of and connected to the central analyser unit via fibre
the filter. optic cables. The transmitter and receiver units are
The prevention of forced deactivation not only positioned several metres apart, therefore enabling
guarantees the compliance with legislative demands as the measurement of large gas volume. A more
a result of the increased process control; it also prevents representative measurement of the CO concentration
excess downtime with the associated financial loss. is achieved compared to a single gas extraction.
Measurement can be safeguarded even during the
Solution filling of the silo, despite the significant increase in
The LDS6 laser diode gas analyser permits direct (in-situ) dust levels.
measurement of the CO concentration right before or If there is a significant increase in the CO concentra-
inside the ESP. A pair of sensors records the measured tion within the silo, the LDS6 delivers a fast and reliable
value, and transmits it to the central analyser unit for signal enabling immediate counter measures to be
evaluation. Since the measurement is practically carried taken.
out in real-time (1 to 3 seconds), it is possible to reduce The fast reaction times obtained due to the in-situ
the unnecessarily high safety margin when defining measurement enable an increase in the threshold levels
GAS ANALYSIS

maximum permissible CO levels, enabling the isolation
level to be increased to around 6 – 8% for example.
As a result, the frequency of faulty shut down of
the ESP is significantly reduced compared to a slow
extractive measurement. Measurements can also be
carried out under high dust loads by observing appro-
priate installation measures. The rugged sensor design
guarantees maximum operational reliability with low
operating costs. Maintenance requirements are low,
and no on-site calibration is necessary.
set for inertisation of the silo. This reduces the number
of false alarms and results in considerable cost savings
for plant operators.
Up to three sensor pairs can be connected simul-
taneously to an LDS6 analyser unit, and can be
positioned up to 1000 m away from the central unit,
thus making it a cost effective method for real-time
measurement of up to three silos. As a result of their
intrinsic safety design, they are approved for opera-
tion in any EEx zone, including those for dust.

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 Combined level monitoring and CO analysis
coal silo monitoring solution
In addition to increasing the complexity of the gas
analysis task, the same high dust levels within the
coal silo also decrease the suitability of traditional
level measurement devices. Contacting technologies
such as Time Domain Reflectometry (TDR) are prone
to breakage and have high maintenance needs, other
measurement technologies fail due to the high dust
levels within the silo, especially during filling.
Accurate level monitoring is vital to safeguarding
the supply of coal for the cement kiln, but the extreme
dust is a challenge for most measurement instruments.
The Siemens Sitrans LR 400 radar transmitter offers
accurate, reliable measurement in these dusty condi-
tions, even during silo filling. The LR 400 is a 24 GHz
radar transmitter using FMCW (frequency modulated
continuous wave) technology. High power, high fre-
quency, and a narrow beam angle combine to produce
excellent reflection characteristics and exceptional
measurement performance on virtually any solids
medium, regardless of the particle size. The strong
signal-to-noise ratio and advanced signal-processing
technology produce reliable readings even through
severe dust, making it ideal for many applications in
the cement industry.
The instrument uses non-contacting technology,
making it low maintenance with no risk of broken or
tangled cables. The benefit is reduced maintenance Figure 7. LDS6 laser spectrometer measurement points for
costs and trouble-free, reliable measurement. It is easy monitoring the coal silo.
to install and commission, and can be programmed
using the infrared intrinsically safe handheld program- and fire (CO measurements upstream of the ESP
mer or with Simatic PDM or a HART handheld device. and in the coal silo).
It offers networking capabilities through HART or l Environmental protection through the control of
Profibus PA. flue gas purification plants and the monitoring of
The narrow horn antenna enables use in access toxic emissions in the exhaust for compliance with
diameters as small as 150 mm. An intrinsically safe current legislation.
option enables use in EExd areas such as the coal silo.
When coupled with the LDS6 laser spectrometer, Gas analysis on the rotary kiln
the LR 400 radar transmitter provides a complete solu- The most important gas analyses for stable operation
tion for monitoring the coal silo, safeguarding both of the cement rotary kiln are carried out at the entry
employee safety and fuel supply. to the furnace.
Complete combustion requires an amount of com-
Continuous extractive gas analysis bustion air dependent upon the type of fuel being
Flue gas analysis using analysers providing continuous used. 1% excess oxygen results in an increased energy
measurements is essential at many points for the consumption of 15 kcal per kg of produced clinker. The
quality of the generated clinker, efficient usage of measuring of carbon monoxide (CO) and oxygen (O2)
fuels, and protection of the environment from toxic enables the plant operator to retain an economical
emissions. During the production of cement, the fuel/air ratio for the primary firing.
largest share of the production costs is for the fuel The concentration of nitrogen oxide (NO) is an
used. One measure to reduce costs is to burn waste important indicator for the combustion temperature.
materials. In Germany, the use of waste materials in Maintenance of a constant temperature in the clinker-
combustion plants is subject to directives for waste ing zone is decisive for the quality of the finished
GAS ANALYSIS

and other combustible materials (17.BImSchV). The
company operating a cement plant is obliged to
limit emissions by means of state-of-the-art technol-
ogy, and to monitor observation of the limits via
measurements.
The main tasks of gas analysis are as follows:
l Optimising furnace operation by monitoring the
combustion process and minimising the use of fuel
without having an effect upon clinker quality.
l Guaranteeing the safety of personnel and plant
equipment by monitoring the danger of explosion
clinker, and therefore the NO analysis provides an
important reference for the product quality and stable
furnace operation. Fast changes in the NO concentra-
tion indicate a fault in combustion. The NO share is
approximately 95% of the NOX share in the flue gas of
cement rotary kilns. It is unnecessary to use a converter
to measure the NO2 component since the trend in the
NO concentration is of greater significance than the
absolute NOX concentration.
Sulfur dioxide (SO 2 ) is produced from the
sulfur content in the raw materials and fuels. Its

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importance is increasing because of the increasing
combustion of waste materials with a high sulfur
content. One of the effects of a high sulfur con-
centration is the increased production of deposits
in the rotary kiln. A sudden increase in the SO 2
concentration provides early information on a
fault in combustion.
Sampling requirements
As a result of the difficult conditions in the rotary kiln,
high demands are placed on the sampling system. The
high gas temperature of up to 1400 °C is especially
problematic, along with the high concentration of dust
of up to 2000 g/m3, as well as the high concentrations
of alkali, sulfate and chloride in the process gas. In
addition, the gas sampling probe is mechanically
endangered by deposits falling down from the kiln
lining.
In particular, high concentrations of sulfur, alkali
and chloride very frequently result in blockages in the
gas paths, necessitating excessively high maintenance
of the sampling system. The
high ambient temperature
means that thermal protec-
tion must be provided for
the probe tube by means
of an appropriate cooling
system. The continuous
measurement is guaranteed
by cyclic blowing back of
the accumulated dust.
FLK sampling system
The FLK sampling system
was specially developed for
use in the inlet chamber
of the rotary kiln. More
than 160 systems are in use
worldwide. Through the use Figure 8. The FLK kiln sampling system: robust and reliable.
of a synthetic cooling agent,
the coolant temperature is
maintained between 160 and 200 °C. This keeps the
temperature of the sampled flue gas significantly
above the acid dew point, (between 140 and 180 °C
depending on the SO2 concentration). Condensation of
flue gas in the probe tube, which can very rapidly lead
to blockages in the presence of dust, is thus prevented
or minimised.
The system consists of the following components:
l A liquid-cooled gas sampling probe for processing
gas temperatures of up to 1400 °C with a gas inlet
that opens on the side, which helps to reduce the
likelihood of blockages. The oval profile of the
probe guarantees a high mechanical stability.
l An electrically heated dust filter for the removal of
dust from the process gas. The electrical heating
system prevents condensation and thus prevents
the caking of solid mass within the filter tube.
l A compressed air purging unit for cyclic cleaning of
the dust filter and sampling probe, and returning
dust into the process. The cleaning program is
started periodically either by the programmable
controller, manually using a push button, or through
detection of a vacuum caused by a blockage in the
gas path.
l Prior to the commencement of purging, the sample
gas path to the analyser cabinet is shut off by a
non-metallic four-way ball valve. To relieve the
sample gas cooler used for gas conditioning, a
corrosion-resistant condensation trap can be fitted
to the compressed air purging unit.
l Automatic extraction unit: in the event of a fault,
the sampling probe is automatically removed from
the rotary kiln in order to protect it against thermal
overloading.
An electric gearmotor is used as the drive, with
a pneumatic motor on standby, should the power
supply be interrupted. Faults which result in immediate
extraction of the probe are:
l Excess temperature in cooling circuit.
l Level of cooling agent below minimum.
l Flow faults.
Heat exchanger unit
The gas sampling probe
is cooled by means of a
non-pressurised air/liquid
heat exchanger. Use of
a synthetic heat transfer
medium permits cool-
ant temperatures up
to 200 °C. This prevents
reduction in the flue gas
temperature below the
acid dew point.
Control and
monitoring unit
All functions of the
gas sampling unit are
monitored and control-
led by a programmable
controller. All parameters such as the frequency and
duration of probe purging can be adapted by the
operator to the plant conditions using a control
unit without the need for programming knowledge.
The controller can be equipped either with a Simatic S7,
Allen Bradley SLC05/500 or Schneider PLC.
User benefits
l Sampling of process gas above the acid dew point
prevents blockages through condensation of flue
gas.
l The use of a synthetic cooling agent prevents
GAS ANALYSIS
furring and corrosion in the cooling circuit, and
requires no protection against freezing.
l Important operating parameters can be optimised
at any time according to the plant conditions using
the built-in operator panel.
l In the event of permanent blockages, the internal
gas sampling tube can be simply and cheaply
replaced following loosening of four screws.
l A short commissioning time of approximately three
to five days. __________________________________u
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