Gas Analysis on Cement Plants

Continuous analysis of process gas is a compulsory

and fundamental task for any cement plant working
in a competitive market. The process benefits are
harvested in a number of areas with very favourable
returns on investment such as optimisation of
combustion, reduction of fuel consumption and
improvement of clinker quality.

Our continuous emission monitoring and reporting

system may be configured to be in compliance with
any legislative demand, allowing cement plants to
focus on producing cement.

July 2008
FLSmidth - Gas Analysis on Cement Plants
Kiln Inlet and Calciner Gas Analysis - KilnLoq

KilnLoq probe mounted Probe Cleaning Water Control GASloq 1200

Panel Panel

Heated Hose

Fig. 1 The FLSmidth gas analysis solution for the kiln inlet is designed on the basis of on-site experience. The equipment
configuration is modular for fast installation and commissioning. The equipment is specially designed for easy trouble-free
operation and maintenance in the very demanding environment and process of a cement plant. All power and external
connections are terminated through the GASloq 1200 panel. Standard interface for FLSmidth Automation ECS is included and
optional remote access can be provided.

Application
The Kiln Inlet gas analysis system is especially designed for the Sustainable operation practice:
highest temperatures and dust loads in cement production. • Reduced greenhouse gasses
Typical applications are kiln inlet, riser duct, calciner and • Efficient utilisation of raw materials
cyclone exit. Through this high temperature gas analysis • Safe production environment.
system, compulsory data are collected for optimizing and
controlling the combustion and the production process of a
cement kiln.
Coaxial filter in heated Filter House
Process objectives Probe Sample End
The typical gasses to be measured in the kiln inlet are:

• Burning balance (O2, CO2) “One Pipe”

• Combustion conditions (CO, CH4, Combustibles) No Obstacles
• Burning zone temperature changes (NO)
• Gas re-circulation and material build-ups (SO2) Gas Sample 180°C

The investment in high temperature gas analysis equipment Fig. 2 During analysis, process gas is sampled through
is very favourable with a typical pay-back time of below 200 the 180°C heated ONE PIPE construction.
days. The process benefits are:

Reduced emission: Access Port

• Optimised combustion
• Use of alternative fuels
Filter Cleaning & “One Pipe”
Economically most beneficial production: Probe Insection Power Cleaning
• Increased production
• Reduced fuel consumption Filter Cleaning
• Reduced clean-out of material build-ups in kiln
Fig. 3 The ONE PIPE simplicity and functionality is as efficient
• Optimised clinker through-put and quality
as a gun barrel. Maintenance and operation is easy with fast,
full length probe inspection through the rear end access port.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

 Kiln Inlet and Calciner Gas Analysis - KilnLoq

Equipment objectives
The analysis equipment is placed right in the middle of a highly than previous available models due to heavy, special high
active and aggressive mineral calcination process. Based on temperature resistant stainless steel together with a multi layer
our large process and operational experience in the cement construction. The probe is cooled by re-circulating cold water.
industry, we have found three main equipment objectives that Using cold water probe cooling gives up to 20% increased
must be fulfilled if the equipment is to be successful: strength compared to hot cooling mediums like e.g. oil cooling,
and water is also much safer in case of leakage.

The probe gas sample path is electrically heated between 180-

350°C in a separate isolated and exchangeable inner pipe.
Through this separation, the gas sampling and probe cooling
is divided to ensure that no condensation will occur inside the
probe.

Due to its heavy construction, the probe is mounted in an

Extraction Device for handling. In case of any operational
problems, the Extraction Device will remove the probe from
the process to a safe location. Automatic periodic probe
extractions ensure that material build-ups on the probe are
removed. An air blaster control is integrated in the system to
remove any material build-up around the probe.

Strong construction, cold water cooling, protection with the

Fig. 4 One of our very satisfied customers in front of the Extraction Device, and removal of raw material around the
KilnLoq probe and analysing system which is made specially probe significantly increase the expected life time and actively
for the environment of a cement plant. The Extraction Device prevent probe damages.
comes with full CE approved protection cover and operates
with a safe, low temperature water cooling system. Reliable - trouble-free operation
The KilnLoq probe and the sampling system for the kiln inlet
Simple - Easy Maintenance application is built with years of accumulated cement process
The design concept of the equipment involved is: “keep it know-how and gas analysis technology. The equipment
simple”. A simple design is the most effective way of achieving control system and choice of components emphasise the
simplicity in the maintenance and operation of the equipment.
The modular system configuration and use of high quality but
conventional components allow the equipment to be operated
by non-specialists. The KilnLoq probe is introducing a truly
revolutionary design to reduce the involved maintenance of Access Port Filter House
the system. The design is based on the unique patent pending
“ONE PIPE” layout of the entire sample path inside the probe “ONE PIPE”
inspired by the simplicity of an air blaster.

No gas analysis probe can be made maintenance free, but the

“ONE PIPE” design makes maintenance as easy as possible.
A quick connector at the access port in the rear end of the
probe gives access to the full length of the probe in seconds
without any dismantling of the probe system or filter house. A
full inspection or mechanical cleaning of the probe filter and
sample pipe can be done in less than a couple of minutes. This
feature is only possible through the “One Pipe” design as no
obstacles like filter elements or pipe bends are found in the
Fig. 5 A pro-active gas sample flow control feature prevents
layout of the probe.
clogging of the probe by removing any obstacle in the sample
pipe before it becomes a problem. The feature is based on a
Strong - Prevents Probe Bending
model of the pressure drop in the “ONE PIPE” sample line.
The KilnLoq probe is strong - more than 8 times stronger

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

Kiln Inlet and Calciner Gas Analysis - KilnLoq

need for practical solutions that are able to operate in the The Probe System
aggressive environment of a cement production process. All The probe is water cooled by a strong
proven solutions from the previous version of high temperature cooling jacket with re-circulating cold
analysis have been integrated into the KilnLoq model. As part water from the Water Control Panel
of our continuous development, features capable of increasing (WCP). Due to re-circulation of water,
the reliability and run-time of the equipment have been the consumption of water and lime is
integrated. negligible. The cooling system works
as a cold ON/OFF full flow system and
The heat input from the kiln process to the probe surface is needs no preheating or adjustments
monitored. This allows the system to determine if raw material during operation. All operational status
is building up around the probe inside the kiln. If material builds is monitored and refill of water is
up, it may become a hazard and cause damage to the probe, automatically done by a solenoid valve.
and the analysis will be effected by the entering of false air. Water Control Panel
With this unique heat input feature, information is provided to
actively remove raw material and monitor the general status of In the probe, a separate and replaceable gas sample probe is
material build-up in the kiln inlet area. electrically heated to 180-350°C and inserted into the cooling
jacket. A heated filter coaxial to the gas sample probe is part
The reliability of the system has been significantly of the “ONE PIPE” probe layout. Due to this construction, the
increased with the two added features. The probe can be inspected and cleaned in its full length without
first is achieved by the “ONE PIPE” design. By dismantling or use of tools. The probe is cleaned by air at
means of the PLC control system the sample customer set intervals controlled by the GASloq 1200 cabinet.
pipe will be cleaned automatically at pre-set From the probe, the gas is sent to the GASloq 1200 cabinet for
intervals. However, if any deviation from the analysis through a 180°C heated sample hose.
normal probe pressure drop over time occurs, a
signal will be generated by the PLC in order to The Extraction Device is a handling and safety device for
start up preventive cleaning of the gas sample the KilnLoq probe. In case of any operational problems, the
pipe. This feature removes any obstacles in the Extraction Device will remove the probe from the process.
sample path before it becomes a problem. The As the Extraction Device operates by two powerful air driven
second feature is a measurement of the heat pistons, the large air receiver of the Probe Cleaning Panels
input from the process to the probe surface. By serve as air supply back-up.
measuring critical deviations in this heat input,
Probe it is possible to predict material buildup in the kiln
Cleaning inlet area around the probe. In this way, the gas
Panel analysis system is not only producing results from
analysis of the gas composition in the kiln but is also providing
information about general raw materials building up in the kiln
inlet before they can be measured by any other devices.

The KilnLoq probe provides the best run-factor ever seen

by any analysis system for high temperature analysis and is
specially made for the cement industry.

System configuration The KilnLoq probe is a patent pending revolutionary extractive

The system configuration comprises of four standard modules. analysis method for the most troublesome process conditions
They all come pre-tested and ready for installation with a on a cement plant. The probe has been specially designed for
minimum of commissioning time. System operation and easy operation and maintenance based on a strong probe
components used are identical for all FLSmidth gas analysis providing a high run-factor and reliability by the simplest
applications, thus allowing easy training and a reduced number design possible.
of needed spare parts.
Please contact us to learn how our kiln inlet gas analysis system
Only well-documented components that have proven their will make you a more competitive cement producer.
ability to handle very aggressive process gases are used.
Material used for all parts in connection with gas is heated
stainless steel, galvanised steel, PVDF or similar.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

 Preheater Outlet Gas Analysis - DDOP

GASloq 1200
Gas Preconditioning
Unit (GMU) and analysis
cabinet.

Dual non cooled probe

type DDOP for continuous
analysis. One probe is
sampling while the other
is cleaned by purging air
Air Power
from the Probe Cleaning
Panel (PCP).

Fig. 6 The modular design is the basis of the “plug and play” installation. The system comes in 3 modules ready for installation
on site: Dual Dry nOn Cooled Probe (type DDOP), Probe Cleaning Panel and GASloq preconditioning and analysis unit.

Application Nitrogen Oxide (NO) is linked to the temperature development

The Preheater Outlet gas analysis system is especially designed in the kiln burning zone. This measurement serves as a backup
and used as basis for interlocking of kiln burner, fan and and reference analysis to the kiln inlet NO measurement. It can
electrical precipitators. When integrated into the FLSmidth also be used if NO reducing measures are implemented into
technology, it can also be used for verifying various steps the kiln system as a controlling parameter.
during kiln startup and shut down. The analysis at this point Sulphur Dioxides (SO2) has been reduced at this measuring
allows for final supervision of the burning and calcination point compared to the kiln inlet. This analysis point is used
process in the kiln system. to monitor the absorption of sulphur in the raw material. The
measurement is most useful in the control and reduction of
Process objectives the SO2 emission from the plant. It can also be used if SO2
The key benefits of the equipment are: reducing measures are implemented into the kiln system as a
- True continuous gas analysis for real inter-locking safety controlling parameter.
- Low fuel consumption
- Reduction of emission Equipment objectives
- Reduce fuel cost by burning waste Only a truly continuous gas analysis system can be used for the
preheater gas measurement. Two probes shifts between each
Our equipment reflects this in the manner of operation and other during purging periods in order to extract gas for analysis
service. Our modular system layout makes it easy to operate. at any time given to avoid “blind periods” which may cause
The Gas Monitoring Unit type GASloq 1200 is equipped with potentially dangerous concentrations of process gas to pass
two parallel sampling systems supplying gas from each of the the measuring undetected and thus cause explosions by the
two probes and sending it to one common set of analyser units filter. As safety is the key issue, no compromise has been made.
at high speed. During service of one probe, the other probe Even though extractive sampling technics are not the fastest
continues the analysis unaffected. possible measuring method,
it offers the safest technique
The most beneficial analysis results are: combining easily verified
calibration and gas analysis
Oxygen (O2) for burning balance control. This measurement together with true continuous
serves as a backup and reference analysis to the kiln inlet gas sampling regardless of
oxygen measurement. It also measures the level of false air process conditions and possible
entering the kiln and preheater system. dust contamination.
Carbon Monoxide (CO) is high concentrations surveillance.
The equipment is born with two extra alarm relay contacts The system only has to make
for direct hot wire interlocking of e.g. an electrostatic one safety interlocking of the
precipitator. process to justify the investment.
Methane (CH4 ) is measured in connection with the use of Running a cement plant without
natural gas as a combustible. The signal is used in the same this equipment is simply not an
manner as the CO analysis. option. Fig 7 Preheater Tower

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

Coal Mill Gas Analysis - Scan System

Fig. 8 The analyser system comprises a

Single Dry Filter Probe (SDFP) and/or a
Single Dry Silo Probe (SDSP), a sample line
and a GASloq gas conditioning system. The
GASloq cabinet module takes care of the
overall system control and operation. All the
components for conditioning of the process
gas as well as the analyser are placed in this
module. Only well documented components
that have proven their ability to handle very
aggressive process gases are used.

Application for conditioning of the process gas as well as the analysers

The coal mill gas analysis is used to avoid self-ignition and fires. are placed in this module. Only well-documented components
Development of dangerous levels of CO are measured in coal that have proven their ability to handle very aggressive process
filled silos if large amounts of coal dust is in storage or packed gases are used.
up. The system is built to measure CO by scanning between
several silos. When a silo is empty, no analysis is needed. The The SDSP silo probe and the SDFP filter probe are able to
O2 measurement is used to check the operation of an inert operate in low temperatures and low dust conditions. The filter
operated coal mill. Since low oxygen process gas is used as is placed inside the process providing gas analysis in process
flow media in the mill to suppress the combustion of the coal, conditions. A Probe Cleaning Unit is not included as the dust
continuous analysis of O2 is very important. content is very low.

Process objectives The coal mill department probes are made from corrosion
The scan system at the coal mill is intended continuously resistant stainless steel. The filter probe can be installed at the
to assist and notify the operator of conditions and give exit of a bag house filter and will, when the filter is not in
adequate warning of potential hazards at an early stage. operation, monitor the development of CO originating from
Subsequent preventative action can then be made to secure packed coal and thereby prevent self-ignition. During operation,
the operation. the CO content can be monitored in the gas passing through
the filter installation. The probe is used in connection with an
Equipment objectives inert operation of a coal mill and the measuring point must
The analyser system comprises a combination of Single Dry Filter be analysing continuously for measuring the development of
Probes (SDFP) and Single Dry oxygen.
Silo Probes (SDSP), sample lines
and a GASloq gas conditioning The silo probe must be installed at the top of the silo in
system. The amount and type order to monitor the development of CO. The probe is made
of probes is dependent on the especially for pressure vessels. Used in a de-dusting cyclone,
actual number of measuring the analysing system only scans this measuring point if the
points. process is not running and coal can be packed in the cyclone.
Fire fighting equipment can be controlled from this analysis.
The GASloq cabinet module
takes care of the overall Standard coal mill watch systems
system control and operation. FLSmidth supplies different solutions from large multi scan
A PLC system controls the analysis systems to small filter and silo watch systems. The
functionality, performance and silo and filter watch systems are small standard systems with
alarm handling of the system limited possibilities in design and functionality. The multi scan
,and an HMI presents the systems are large multi point analysis systems for multiple silo
present status and operation of and filter scanning. The multi scan systems can be designed for
the system. All the components Fig. 9 Coal Mill Silos almost any kind of plant type and design.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

 GASloq Systems

Gas Monitoring Unit GASloq 1200: GASloq CUBE housing:

The PLC control and gas conditioning equipment is placed in A special housing GASloq CUBE can be supplied as a plug-and-
the GASloq 1200 cabinet. The GASloq 1200 system is designed play installation with ideal ambient installation conditions for
to sample, condition and analyse process gas or emission gas the analysers. As an alternative to building an analyser shelter
and to present the measurement result in a display and/or to on site, the GASloq CUBE is a solution with obvious advantages.
the plant control system. It provides large reductions in the overall installation cost and
will also prove
Extractive gas analysis means, contrary to in-situ gas analysis, most beneficial
that a sample is taken continuously from the process for in the pursuit of
analysis. The gas is sampled through a sample probe and a better run factor
sample hose to the conditioning unit in the GASloq gas analysis for the analysing
system where the gas is conditioned and analysed. equipment. This
solution will
Operation and surveillance of system status, performance, reduce needed
alarm report, event report and calibration is conducted by a installation and
colour touchdisplay on the front of the cabinet. The user can commissioning
easily adjust all relevant parameters of the system and check time and provide
system performance. The 180°C hot gas received from the the best possible
probe is cleaned by means of special aerosol filters. The gas is conditions for
dried in a cooler. service access.
The GASloq CUBE
A peroxide dosing system can be enabled if the process gasses cabinet samples,
contain high levels of sulphur, as frequently seen in pet coke conditions and
and waste fired kilns. Communication to the control room is analyses process
made by hard-wire or through a serial connection offering all gas and presents
relevant system information. the measurement
to the plant control system. The CUBE is equipped with:

• Rittal cabinet for power compartment

• HMI colour touch display
• PLC type ABB or Siemens
• Analysers for e.g. O2, CO, CH4, NOX and SO2
• Gas sampling membrane pump, solenoid valves, flow
valves and regulator
• Flow measurement and alarm
• Calibration control
• Room light and airconditioning.

The inside of the shelter is pleasant and well organised. The

ambient temperature is controlled by the airconditioning. Thus,
the shelter provides an ideal working environment for both
equipment and maintenance staff. All system components
are selected on the basis of our process knowledge and have
proven their abilities on site in respect of quality, ease of
maintenance and resistance to corrosive gases. Comparing
the cost on erecting a building locally, the overall project costs
easily come out in favour of the GASloq CUBE.

Utility equipment:
Together with the GASloq gas analysis system, a wide range of
accessories can be delivered. Calibration gases, parts for start-
up, wear and spare parts, commissioning and service contracts
are among the most used accessories delivered together with
a complete gas analysis solution.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

CEM - Continuous Emission Monitoring

Application
During the last years, requirements for Continuos
Emission Monitoring has increased significantly
in order to fulfill the demands set by the local
authorities.

Due to an increasing number of demands on

protection of the environment, most plants must
now deal with even greater reductions on emission
values and the reporting of these. On the other hand,
plants are investing in CEM systems in order to burn
waste, obtain ISO 14000 certification and introduce
a “Green Protection” as a value driver.

The benefits of the CEM system are

• Reduction of harmful emission gasses
• Reporting of emission values
• Reduction of fuel consumption through
waste burning
• Income on disposal fees through waste
burning
• Fulfilment of local emission legislation Fig. 10 Emission monitoring system placed on stack

Legal specifications from local authorities set up requirements the advantage of being able to combine the legal demands with
for the analytical components needed on various configurations. production gains and hereby pursuit a plant emission strategy.
Typical approved analytical technics are specified together
with a demand for e.g. sensitivity, availability, calibration and Process objectives
validation methods. The CEM system installed in the stack measures both the
concentration (in mg/m3 or ppm) and the total emission of
Standardisation has been implemented in some countries/ the various polluting gasses and dust. To report these data, a
regions; other areas have specified their own unique set of conversion to standardised physical values must be calculated
rules. Our large international experience allows us to choose in order to compare the data with emission limits set by the
a setup of instruments and measuring methods in compliance enforced emission legislation. As some of the components
with every one of these rules and in this way provide the most measured are very small in concentration, and the demand
beneficial solution. Our independency as supplier gives us for precision set by legislation is very strict, the demands for
the freedom to choose and implement the Best Available high quality precision analysis with proven repeatability is
Technology (BAT). Being cement process specialists, we have obligatory. Two different technics are used to collect data: in-
situ and extractive.

In-situ measurement is a method where the analyser is

mounted directly on the stack, and the measurement is made
in the stack. The measurement is made at actual process
temperature, pressure, water content and dust concentrations.
Thus, the meaurement system must be able to operate under
these conditions, and the normalisation of the measurement
must be done externally.

Extractive measurement is a method where process gas is

extracted from the stack and transported to the gas analysis
system. It is normally done in fixed physical conditions and is
thus not affected by changing process conditions. It is able to
handle high dust loads. To avoid wash out of gas components,
a heated sample system is used. Validation and calibration can
be done with a test gas allowing easy quality assurance of the
Fig. 11 On site installation with dust, flow and gas analysers equipment.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

 CEM - Continuous Emission Monitoring

Sample probe for In-situ gas

extractive gas analysis. analysis
In-situ measurement for by LASER
dust, temperature and measurement
pressure principle

Gas Monitoring
Unit GASloq
1200 or multi
In-situ ultra
component
sonic flow
analyser type
measurement
FTIR
Fig. 12 The configuration of the CEM equipment must reflect the legislation enforced by the local authorities or a specific permit
for a given plant. Demands on CEM systems can be limited to a dust monitor or to a complex system comprising of dust, flow,
pressure, temperature, gas analysis and data acquisition system. FLSmidth can provide the most beneficial solution as we are
not dependent on any specific sub-supplier.

Equipment objectives
The choice of configuration type (in-situ or extractive) is
very complex and is often determined by limitations in the
legislation or by the given process conditions in the stack.
FLSmidth’s default configuration consists of a combination of
the two techniques. For dust, flow, temperature and pressure,
we normally use in-situ measurements. For gas analysis
components, we use a heated extractive system. The reporting
system must be in accordance with the legislation and able
to produce the requested reports. Security of data is a major
concern. FLSmidth is capable of supplying a stand-alone PC
solution or a total integration into a plant central control
system.

ECS/StackGuide
ECS/StackGuide is FLSmidth’s cost-efficient product to Fig. 12 Continuous Emission and Monitoring (CEM) and
guarantee all emission monitoring and reporting requirements reporting system. Optional incorporation with the ECS/
in the cement and waste incineration industries. ECS/ StackGuide system packages available for full plant integration
StackGuide is a CEMS package with these main benefits: and safety replication of data.
• Guarantee for complete fulfilment of emission legislation
requirements anywhere in the world Conventional fuels (coal, oil, gas etc.)
• Easy customisation to any special requirements for central, Requested Components (RC): CO, NOX, SO2, Dust
local or plant authorities Utility Components (UC): O2, H2O, flow, temperature, pressure,
• Improving emission statistics by early warning of plant calculation/ reporting
operators about any upcoming emission violation
Waste fuels
Gas components to be measured on the stack Requested Components (RC): CO, NOX, SO2, THC, HF, HCl
The measured components can be divided into groups, Utility Components (UC): O2, H2O, dust, flow, temperature,
Requested Components (RC) as specified in the legislation and pressure and calculation/reporting
Utility Components (UC), which are needed to perform the
conversion of data into normal values. For more information on the exact configuration of your
emission reporting system, please contact any FLSmidth
representative or visit our website www.flsmidth.com/gas.

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

ECS/StackGuide - Emission Reporting

ECS/StackGuide If the raw data exists in ECS control systems, ECS/StackGuide

ECS/StackGuide is FLSmidth ’s cost-efficient product to guaran- supports the redundancy of the control system to collect the
tee all emission monitoring and reporting requirements. maximum available data from the servers. In addition, a catch-
up function in ECS/StackGuide makes sure that if the data
Combustion related plants such as cement and waste collection is interrupted, the missing data will be collected
incinerations plants all over the world are facing a growing automatically in order to avoid data gps in the CEMS database.
amount of rules and demands by various authorities on how Lack of data in the CEMS database may result in penalties.
to report their emissions from their production. The term
“CEMS” (Continuous Emission Monitoring System) is applied Real-time monitoring
for a complex of requirements for system configuration, ECS/StackGuide can provide an environment in which the plant
monitoring roles, data validation methods and reporting types operators may monitor the current values of the emission.
in the emission reporting demand. These values are not only the traditional raw values, but the
normalised and validated values that are eventually going to
ECS/StackGuide is a CEMS package to accomplish these affect the historical emission report in the historian part of
requirements. The main benefits of this package are: the system. With configurable alarm limits, the operators will
be able to take corrective actions in the process to minimise
• Guarantee for complete fulfilment of emission legislation the emission violations. The real-time part of the system is a
requirements anywhere in the world natural part of the ECS control system. However, it may also be
• Easy customisation to any special requirements for integrated with other control systems as on-line imported and
central, local or plant authorities displayed data in the existing control system.
• Improvement of emission statistics by early warning of
plant operators about any upcoming emission violation Safe data storage
All the retrieved raw data are kept intact. This means that the
Cost-efficient solution data validation of the raw values will only produce new data
instead of deleting or manipulating the raw data. Keeping the
raw data unchanged is not only crucial for the legislations,
but also enables the user to “simulate” tighter emission
requirements to forecast future investments in the process.
The data storage media of ECS/StackGuide is the industry-
standard MS-SQL database system.

General features
• Historical databases and data access
• OPC data access
• Dedicated reporting package
• Built-in MS-Excel add-ins for report customisation
• Advanced trending software
• Data editing
• Web access
Traditionally, the CEMS solutions have been developed on a • Windows 2000, XP and 2003
highly plant-specific basis. In order to meet the demands for • Terminal server support for remote access
data validation and monitoring roles, parts of the solutions • Service release and hotfix support
have traditionally been implemented at the PLC level with • Realtime and historic emission control
programming intensive effort resulting in working, but quite • Store data for years
complex solutions that are difficult to maintain in long-term. • Emission data
Other parts of the solution are traditionally implemented as • MS-SQL Server relational database
special data retrieval and reporting system with customised • Advanced data validation methods
programming approaches. • Data tournament for dual ECS control system sources
• Catch up to retrieve lost data from down periods (by
ECS/StackGuide is the most professional and cost-efficient use of the ECS solution)
CEMS application with many advantages some of which are • Firewall between plant control and administrative
listed here: system
Secured data retrieval

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

 Module data

Module description Size: h x w x d (mm) Consumptions Operational range IP

GASloq 1200 1200 x 2100 x 600 Power: 3 x 380 V- 3 x 460 V Ambient: +5 to + 40°C,
54
Mat.: Painted carbon steel 350 kg 50/60 Hz dust and vibration free

GASloq 600 (only used for

600 x 1012 x 515 Power: 3 x 380 V- 3 x 460 V Ambient: +5 to + 40°C,
low-cost coal mill systems) 54
150 kg 50/60 Hz dust and vibration free
Mat.: Painted carbon steel
Power:
Supply from GASloq cabinet Ambient: -10°C to +55°C
Water Control Panel 1980 x 1200 x 800
Water consumption: protected from heat
(WCP) 320 kg 54
0 m /h - 1” union radiation (Below zero
Mat.: Galvanised steel 200 ltr.
Water re-circulation: possible with glycol)
4 m /h -1” union
Process: 400°C
KilnLoq 400 probe 400 x 200 x 3000 Power: (higher temp. on request)
(kiln inlet/wet kiln) 150 kg Supply from GASloq cabinet Dust load: 1000 g/Nm3 54
Mat.: Stainless steel Insertion length 2000 mm Air Supply from PCP (higher dust load on request)
Ambient: : -10°C to +55°C
Power:
Process: 900°C
Supply from GASloq cabinet
KilnLoq 900 probe 400 x 200 x 3000 (higher temp. on request)
Air Supply from PCP
(calciner) 150 kg Dust load: 1000 g/Nm3 54
Water:
Mat.: Stainless steel Insertion length 2000 mm (higher dust load on request)
Supply from WCP - 1”
Ambient: : -10°C to +55°C
union
Power:
Process: 1200°C
Supply from GASloq cabinet
KilnLoq 1200 probe 400 x 200 x 3000 (higher temp. on request)
Air Supply from PCP
(kiln inlet/calciner) 150 kg Dust load: 1000 g/Nm3 54
Water:
Mat.: Stainless steel Insertion length 2000 mm (higher dust load on request)
Supply from WCP - 1”
Ambient: : -10°C to +55°C
union
DDOP probe L = 740 mm Process: 400°C
(preheater outlet) 24 kg Air: Supply from PCP Dust load: 200 g/m3 54
Mat.: Stainless steel Insertion length 400 mm Ambient: : -10°C to +55°C

SDSP probe Process: 200°C

L = 220 mm
(silo probe) Dust load: 2 g/m3 54
25 kg
Mat.: Stainless steel Ambient: : -10°C to +55°C

SDFP probe Process: 200°C

L = 630 mm
(filter probe) Dust load: 2 g/m3 54
15 kg
Mat.: Stainless steel Ambient: : -10°C to +55°C

Process: 600°C
SP2000-H probe L = 1000 mm
Air: Supply from PCP Dust load: 250 mg/m3 54
Mat.: Stainless steel 15.4 kg
Ambient: -10°C to +55°C

Table 1: List of module data

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008

Company profile

Company profile
FLSmidth A/S forms part of the FLSmidth Group, an sound basis for supplying customers with the technological
international group supplying process know-how and total know-how needed, and we are able to deliver the best
lines of machinery, mainly to the cement and minerals suitable product for the job and the customer.
industry.
Power plants, waste incineration plants, refineries, district
FLSmidth A/S has more than 30 years of experience within heating stations, cement plants as well as many companies
gas analysis and detection and has grown into one of the within process industries are among FLSmidth A/S’s regular
most important companies within measurement and control customers, and over the years our technical department has
of polluting gasses in primarily the cement and combustion created a confident relationship to technical advisors both at
industries. home and abroad.

Our success is based on a dedicated and competent workforce Our team of service engineers are fully trained in projecting
as well as reliable business relationships both with customers and servicing the highly complex instruments and analysis
and suppliers. We believe in punctual deliveries at the agreed systems. A complete solution includes pre-projecting, delivery
cost and in accordance with the promised specifications. We including documentation, commissioning, and training as
will not be dependent on one single supplier and thus, we are well as maintenance on site.
general agents for suppliers such as ABB, Crowcon, Durag,
Emerson and NEO Monitors. This way, FLSmidth A/S has a

Addresses
Main office Copenhagen office Worldwide

FLSmidth A/S FLSmidth A/S We are represented by any FLSmidth office in your
Klostermarken 6 Høffdingsvej 34 area. Please contact any local office for further
DK-9550 Mariager DK-2500 Valby information or visit our website containing links
Tel.: +45 7010 2277 Tel.: +45 7010 2277 and adresses to the nearest office.
Fax.: +45 7010 2288 Fax.: +45 7010 2288

www.flsmidth.com/gas

FLSmidth - Gas Analysis on Cement Plants, rev. July 2008