Gas Sampling System: ProKiln GAC400

In the last several decades, the use of alternative fuels in the cement industry has skyrocketed. This offers advantages for environmental impact and energy efficiency, but it also raises new difficulties that affect the process and the kiln inlet measurement.

The fourth generation of ABB for gas sampling at the calciner and kiln inlet in the cement industry is called ProKiln. The premium product was created to adapt to the evolving conditions of cement plants’ processes due to the increasing use of alternative fuels.

Overview

The Premium Solution for Cement Plants with Increased Use of Alternative Fuels

Cement production requires significant energy, and most plants aim to employ alternative fuels to decrease environmental impact and improve process efficiency. According to the European Cement Association, there are no technical restrictions on cement plants using alternative fuels up to 95%.

Despite the obvious benefits to the economy and environment, the industry is advancing quickly in this direction, which creates new obstacles for machinery and processes.

To address the changing process circumstances, ABB and FLO2R have collaborated to provide a premium product that assists cement factories in meeting their objectives. With 60 years of combined knowledge, ABB created its fourth-generationkiln inlet system.

ProKiln – The Next Generation is Powerful!

The ProKiln consists of a control unit, a cooling unit, and a retraction unit. Two air blasters allow the retractor to thoroughly clean the probe tube. Thanks to the unique nozzle design, the pressurized air is channeled in multiple streams to guarantee the probe tip is cleaned as effectively as possible.

A two-layer filter is implanted into the probe and can be readily cleaned with air blasters to prevent a mix of sample and dust. Furthermore, thoughtful construction enables manual cleaning and maintenance without requiring specialized knowledge, resulting in a greater than 95% availability rate.

The technology is offered in a double probe configuration to help cement plants achieve 100% availability.

The Unique Features of ProKiln:

Effective cleaning with two air blasters

Filter in the tip of the probe to ensure no mixture of sample and dust

Limiting direct dust flow via a tip shield

Innovative and unique nozzle design

Thoughtful design enables easy manual cleaning

No moving parts

Easy operation via touch panel

Combinable with AO2000 system and 3rd party analyzers

Available as single and double probe configuration

Data

ProKiln Consists of the Following Three Modules

Retraction device equipped with an electrical motor and chain-driven water-cooled probe

Cooling unit with a heat exchanger and a cooling water circulation pump

Control unit with an industrial controller, including a color touch panel

Retraction Unit

Automatic oven flange closure

Cooling water tubes

Air blaster tubes

Heated sample gas line

Available as single or double probe

Probe length of 1.5 m/2.0 m/2.5 m/3.0 m/3.5 m

Electrical motor by default

Pneumatic motor with air tank to cover power failure (optional)

Control Unit

The menu-driven industrial controller, which features a touch panel, runs the whole system. The operator can configure cleaning cycles, limit levels, and periodic sampling according to their needs without sophisticated PLC programming.

Cooling Unit

Owing to the prevailing conditions, the sample probe must be cooled. ABB’s cooling system employs an open vessel and a non-pressurized water circuit for safe and environmentally responsible cooling.

Capacity water tank: 300 l

Controlled temperature 75 to 85 °C (167 to 185 °F)

Circulation 6 to 7 m³/h

Drinking water quality, anti-freeze agent necessary at ambient temperature <0 °C (32 °F) or/and optional heater in water tank

Service

ABB provides a wide range of services, such as the following, to assist users and their processes:

Product commissioning

Maintenance and field services

Repairs

Spare parts services

Training