Integration of imaging pyrometry into the Wampum Plant automation project [cement plant]

The measurement of the flame temperature and burning zone conditions in cement kilns has long been considered absolutely critical in maintaining optimum clinker production levels. This process control has evolved over the years; from the well-trained eye of a seasoned kiln burner to the dual imaging pyrometry technology used to continually monitor cement kiln burning zones. This device easily integrates into any of today's sophisticated control systems, and quickly becomes a critical link in establishing a control strategy for kiln operation. This paper spotlights the installation and operation of three Spyrometer/sup TM/ systems at Medusa's Wampum facility (USA) during the plant's 1995 automation project. The camera's microprocessors link directly to the remote I/O racks of the new PLC-based control system. So they not only provide a continual window into all three burning zones, but they monitor six temperatures at operator specified windows. These inputs can also be used as a BIF regulated waste fuel interlock or as an expert system control parameter. The data generated from the pyrometer's temperature measurement can also be used in an effective clinker quality control program. By coupling clinker microscopy and cement physical testing with the trended data, tangible performance improvements are demonstrated for not only the product, but with the process operation.