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Solution Description

Infrared thermal imaging can monitor the temperature field of the rotary kiln body in real time, warn of refractory material damage and abnormal sintering of materials in the kiln, and provide key data support for kiln body life maintenance and calcination process optimization. The rotary kiln shell is the core component of the cement plant's clinker burning system. Its main process revolves around the heating, calcination and chemical reaction of materials in the kiln.

System features:

1.Thermo camera has high-temperature  resistant  design, withstanding  up  to  200℃ ambient  temperature

2.High degree of protection up to IP66

3.The window is automatically blown, and there is no need to manually clean the window regularly

4.Full-screen  real-time temperature  measurement, wide  coverage;

5.Thermal image camera does not depend on the system platform, and can directly log in to the IP page to access the image and configuration, and can directly output the alarm signal to the PLC or alarm;

6.Infrared thermography camera support onv if protocol, can access mainstream NVR;

7.The temperature data can be connected to the LED screen and PLC;  Motorized/autofocus, focus  operation  through  software  at  any  time;

8.The temperature measurement range can be customized, and the maximum support is -40℃ to 2000℃;

9.The temperature measurement accuracy is better than±2℃ or±2%;

10.It supports modb us protocol and can be connected with the DCS system for temperature data transmission.

Benefits brought

• 

  Quantifying the degree of refractory brick wear: A cement company discovered the wear of refractory bricks on the kiln head cover through thermal imaging, and stopped the kiln in time for repairs, avoiding production losses caused by burn-through (the repair cost of a single burn-through exceeded 500,000 yuan).

• 

  Tracking the spalling process of refractory materials: Before refractory materials spall, the temperature of the local area will rise suddenly due to abnormal heat conduction (such as temperature rise > 5°C per minute). Thermal imaging can capture the temperature change rate in real time and warn of spalling risks 4-8 hours in advance.

• 

  Kiln deformation and deflection monitoring: Kiln bending or deflection can cause local shell overload and abnormal temperature distribution (e.g. shell temperature at the bend is 15-30℃ higher than the normal area). Thermal imaging can be combined with kiln rotation speed (usually 1-3rpm) to analyze the temperature field fluctuation pattern and guide the adjustment of the support roller position.