Introduction To Industry Scenarios
The core of cement production is "two grinding and one burning" (raw material grinding → kiln calcination → cement grinding), with extremely harsh working conditions: high temperature (120-180 ℃), high dust, strong vibration, strong electromagnetic interference, easy agglomeration of powder/slurry, acid and alkali corrosion, and 24-hour continuous operation.
Typical measuring points:
Raw material preparation: raw material silo/fly ash silo material level, raw material slurry pool liquid level, homogenization silo pressure, mill lubrication station oil level
Clinker calcination: kiln head/kiln tail pressure, cooling fan chamber pressure, waste heat boiler steam drum level, kiln cooling water tank level
Cement grinding: cement silo level, mill lubrication station pressure, circulating water level, additive storage tank level
Public auxiliary/environmental protection: sewage treatment tank level, acid-base regeneration tank level, compressed air pipe network pressure, fire water tank level
Adapt to Core Products
QDY30A High Temperature Dust Type Input Liquid Level Transmitter (180 ℃, Anti Dust/Agglomeration, 316L, IP68, Anti Vibration)
QDY60 series static pressure liquid level transmitter for raw materials/cement slurry (anti powder deposition, anti blockage, long-term immersion, zero stability)
QDW90A-3051 High temperature flange liquid level transmitter (180 ℃, flat diaphragm anti scaling, special for viscous/slag containing slurry)
QDKG high-temperature dust type intelligent pressure switch/transmitter (0.075 level, 180 ℃, explosion-proof Ex d II CT6, anti vibration, kiln pressure specific)
GLG high dust strong interference signal isolator/RS485 (2500V isolation, anti frequency converter/large motor interference, long-distance transmission)
S803/SS803 high dust digital display instrument (IP65, dustproof and explosion-proof, high brightness LED, local alarm, kiln area/mill wall mounted)
Product Function
QDY30A/QDY60+QDW90A-3051 liquid level class (slurry pool/silo/boiler)
Raw material slurry pool/homogenization pool liquid level: resistant to high temperature, anti caking, anti mud, real-time monitoring of slurry liquid level, linked with mixer/feed valve to ensure stable raw material concentration, uniform calcination quality, and clinker strength compliance.
Waste heat boiler steam drum liquid level: QDW90A is resistant to high temperature and high pressure, with a flat membrane to prevent scaling, accurately controlling the steam drum water level, preventing dry burning/full water accidents, ensuring stable waste heat power generation, and improving energy recovery rate.
Cement/raw material warehouse material level: prevent dust accumulation, long-term stability, monitor the material level in the warehouse, link the feeding/discharging belts, prevent tank overflow/material breakage, ensure continuous production, and avoid environmental dust.
Grinding machine lubrication station oil level: 316L anti-corrosion, anti oil pollution, monitoring oil level, linked oil replenishment/alarm, preventing oil shortage and burning of bearings, ensuring continuous operation of the grinding machine, and reducing shutdown losses.
QDKG high-temperature dust type pressure switch/transmitter (kiln pressure/air pressure/oil pressure)
Kiln tail/kiln head pressure (micro positive pressure): 0.075 level, high temperature resistance, explosion-proof, precise control of kiln pressure micro positive pressure, preventing cold air from entering the kiln for cooling, preventing hot gas from leaking and burning refractory bricks, reducing energy consumption, and extending the life of kiln lining.
Cooling fan chamber pressure: anti vibration, high temperature type, monitoring cooling air pressure, adjusting fan speed, ensuring uniform cooling of clinker, improving clinker grindability, and reducing grinding power consumption.
Grinding machine lubrication station pressure: high-precision, impact resistant, monitoring oil pressure, preventing overload/oil breakage, protecting grinding machine bearings, and reducing equipment failures.
Compressed air network pressure: intrinsically safe explosion-proof, long-term stable pressure, monitoring air pressure, ensuring the stability of pneumatic valves/actuators, and avoiding process control caused by insufficient air pressure.
GLG high dust strong interference isolator (strong interference in kiln area/grinding room)
Kiln area/mill frequency converter/large motor interference: 2500V isolation, common mode rejection ≥ 60dB, cutting off ground loop, suppressing peak interference, DCS signal no drift/jump, no false interlocking, ensuring continuous production.
Long distance signal (kiln area → central control/grinding room → scheduling): RS485+Modbus, signal attenuation free, packet loss rate<0.1%, real-time data upload, stable traceability.
S803/SS803 high dust digital display instrument (on-site/kiln area wall mounted)
On site display in kiln area/grinding room: IP65 dustproof and explosion-proof, high brightness LED, high temperature resistance, intuitive reading during inspection, no need to enter high-temperature dust areas, safe and efficient.
Over limit alarm/interlock: relay output, linked sound and light alarm, emergency stop/valve closing, 1-second response, anti tank overflow/material breakage/overpressure accident.
Data upload/accumulation: Modbus communication, connected to cement MES system, energy/water consumption statistics, fault tracing, meeting the requirements of intelligent manufacturing in the cement industry.
Addressing Industry Issues
High dust, high temperature, and strong vibration make instruments prone to damage
Ordinary instruments can become clogged, drift, or damaged after 3-6 months, with frequent shutdowns for replacement, affecting continuous production, and high maintenance costs.
Inaccurate kiln pressure/liquid level control, high energy consumption+unstable quality
Large fluctuations in kiln pressure, heat leakage/cold air intake, high coal consumption per ton of clinker; The slurry level is unstable and the raw material concentration fluctuates, resulting in substandard clinker strength.
Strong electromagnetic interference, signal jumping and false interlocking
Interference from frequency converters/large motors, DCS false alarms, false shutdowns, material breakage/tank leakage, single accident losses of millions.
Danger of manual patrol inspection+low efficiency
High temperature dust in kiln area, high altitude of silo top, high risk and low efficiency of manual material level measurement/meter reading, data lag and untimely adjustment.
The environmental pressure is high, and the fines for emitting cans/dust are high
The monitoring of material levels does not allow the emission of cans and dust, and the environmental fines are 100000 to 500000 yuan per occurrence, which affects the credit of the enterprise.
Direct Customer Benefits
Quality and Capacity Returns (Core)
Accurate control of kiln pressure/liquid level: The stability of clinker strength is improved by ≥ 90%, the qualification rate is improved by ≥ 98%, and the product premium is increased by ≥ 2%.
Continuous operation: instrument failure rate reduced by ≥ 85%, annual effective production time increased by ≥ 15 days, and production capacity increased by ≥ 4%.
Prevent material breakage/tank overflow: Reduce unplanned downtime by ≥ 90%, and avoid downtime losses of ≥ 3 million yuan per year.
Energy saving and consumption reducing benefits (direct savings)
Stable kiln pressure: The coal consumption per ton of clinker is reduced by 3% -5%, and the annual coal savings of a million ton cement plant are ≥ 30000 tons, saving coal costs ≥ 2.4 million yuan.
Stable waste heat power generation: power generation increased by ≥ 5%, annual power generation increased by ≥ 2 million kWh, and electricity cost savings increased by ≥ 1.6 million yuan.
Energy saving of grinder: precise adjustment of cooling air pressure, reducing electricity consumption by 2% -3% per ton of cement, saving energy of ≥ 1 million kWh per year, and saving electricity costs of ≥ 800000 yuan.
Safety and environmental benefits
High temperature explosion-proof+isolation: The risk of sparks in the kiln area is reduced to 0, and the safety accident rate is reduced by ≥ 95%.
Accurate monitoring of material level: 100% reduction in container dust accidents, avoiding environmental fines, and meeting ultra-low emission requirements.
Maintenance and labor benefits
High reliability design: The instrument has a lifespan of 2-3 years, with annual maintenance costs reduced by ≥ 75% and spare parts/labor expenses reduced by ≥ 400000 yuan.
Unmanned operation: Reduce manual inspections by ≥ 80%, save labor costs of ≥ 180000 yuan per year, and eliminate the risk of high-altitude/high-temperature operations.
Management and compliance benefits
Accurate and traceable data: meets the requirements of cement MES/ISO system, the data is authentic and tamper proof, and improves the level of management refinement.
Intelligent upgrade: Connected to the smart cement platform, remote monitoring/scheduling, management efficiency improved by ≥ 55%, in line with the national cement intelligent manufacturing and ultra-low emission policies.
