Cooler scanner technology [cement plant control]

Pretoria Portland Cement (PPC) is the largest of three cement manufacturers in South Africa. In total PPC holds approximately 45% of the total cement market in the country and also exports cement to neighbouring countries. The company was founded in 1892 and currently operates seven cement factories and one lime factory. The latest of the cement factories is the Dwaalboom factory located 360 km west of Johannesburg. The factory consists of a five stage preheater kiln with a retrofit controlled flow grate cooler system. A CoolScanner system from FLS Automation was installed on the cooler during the retrofit. None of the operators on the plant were familiar with grate coolers, but with the help of the thermal image generated by the cooler scanner system, they have been able to effectively control the process without any significant difficulties. The system has enabled them to eliminate the formation of red rivers and localised air blow through on the grates. The thermal image facilitates much better control on the cooler and secondary air temperature thus resulting in process stability and optimisation. It is the general feeling at PPC that without the cooler scanner system it would be much more difficult to operate and control the grate cooler and therefore this system will become part of the standard installation with any grate cooler system.