Dust Monitoring in Cement Manufacturing
Earlier filter-failure detection, better process visibility and reliable emissions monitoring
Multinational cement producer
Challenge: product loss
Solution: continuous dust monitoring expanded to several sites
Continuous dust monitoring at key points in cement production helps plant operators detect filter failures earlier, reduce product loss, target maintenance, improve filtration control and support emissions compliance.
The challenge
Cement production relies on dust collection throughout crushing and milling, the preheater and kiln, clinker handling and milling, and packaging. Deteriorating or broken filters can release valuable material from the process, increase particulate emissions and create avoidable maintenance and downtime.
A multinational cement producer was concerned about product loss and wanted better control of its filtration systems. The plant relied on differential-pressure gauges and visual indications of filter failures, but these methods did not provide sufficiently early or precise warning.
The solution
The plant installed Sintrol Snifter monitors on the outlet ducts of its baghouses and four S303 trend monitors on the inlet ducts of its stacks. The monitors were connected to Sintrol DustLog software for centralized monitoring.
The combination gave operators earlier visibility into deteriorating or ruptured filter bags and helped them identify the affected baghouse before significant changes were visible in differential pressure.
Results
From the original installation to plants in four countries.
The earlier warning allowed the plant to isolate a malfunctioning baghouse compartment, take corrective action sooner and reduce the amount of cement product being lost to the atmosphere. The company subsequently deployed Sintrol solutions at plants in four countries.
- Earlier detection of filter deterioration and bag failures
- Faster identification and isolation of the affected baghouse compartment
- More targeted maintenance and reduced product loss
- Better visibility into filtration performance
John Korpi
Area Sales Director
Dust Monitoring Solutions
How it works
Sintrol’s probe-based dust monitors use Inductive Electrification technology. When solid particles contact or pass close to an insulated probe, they generate an electrical signal. Sintrol’s signal-processing and filtration algorithms convert this signal into an output that indicates changes in dust levels for filter, process and emission monitoring.
Dust monitoring across the cement process
Crushing and milling: Monitoring downstream of dust collectors helps detect filter deterioration or breakage and limit the loss of limestone and other raw materials.
Preheater and rotary kiln: Filter-leak detection and continuous trend monitoring provide early warning of changes in dust levels and support filtration-system control around kiln exhaust and stack measurement points.
Clinker milling: Early detection of filter failures helps retain product in the process and enables operators to respond before losses increase.
Packaging: Monitoring at final dust-collection points helps identify cement escaping from the process during transfer, packaging and shipping.
Relevant products
Please note: Some products referenced in this case study may be earlier-generation models. The products presented below represent Sintrol’s current solutions for these applications.
Sintrol
S101 / S103 Ex Filter Monitor
Reliable S100 Dust Monitors for broken bag detection. Real-time, ATEX Zone 22 approved, easy setup for ducts up to 800 mm.
Sintrol
S203 / S203 Ex Dust Monitor
Sintrol S203 Dust Monitor is used as a continuous trend monitor to see performance of the filtration systems. Perfect to be used after any filtration system or in common line channels leading into the emission points of a plant.
Sintrol
S303 / S303 Ex Dust Monitor
Sintrol S303 is a continuous dust monitor that gives plant operators ability to see the performance of their filtration system over a period.
Sintrol
S305QAL / S305QAL Ex Dust Monitor
S305QAL is an EN15267-3 QAL1 certified stack monitor for official particulate emissions measurement. Reliable, low-maintenance, and robust, it is approved for use e.g. in waste incineration and combustion plants.
Sintrol
S304QAL-L Filter Leakage Monitor and S304QAL-D Filter Dust Monitor
S304QAL series instruments are designed to accurately detect dust leakages or to monitor filter performance in highly demanding industrial processes found in the industrial environments.
Sintrol
S304 / S304 Ex Dust Monitor
S304 / S304 Ex dust monitor provides accurate and fast dust monitoring for process control and emissions compliance. With a 0.01 mg/m³ detection limit, versatile outputs, and robust design, it ensures reliable performance in applications such as baghouses, cyclones, dryers, and other dust collection systems.