1. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 1 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Solutions for the Cement Industry Applications FLK sampling system Kiln inlet Gas flow Gas conditioning Installation Benefits ROI

2. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 2 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Applications of gas analysis systems in Cement Plants Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

3. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 3 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Gas analyzer equipment in cement works must be able to withstand a very tough environment:  high gas temperature up to 1400  C  high dust concentration up to 2000 g/m 3  high content of Alkalis, Sulfates and Chlorides  in addition, high level of mechanical stress and strain Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

4. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 4 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Conventional gas sampling systems with water cooling have a number of serious weak points:  they block up easily because of the condensation that forms due to the low operating temperature  lime deposits and corrosion with water as coolant  caking of material on the probe causes excessive mechanical stress  High cost for maintenance and low reliability Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

5. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 5 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling system The Problem and our Solution  Formation of condensation The operating temperature of 200  C at which our probe operates is above the dew point of the flue-gas and the acid.  Lime deposits and corrosion with water as coolant Using a special synthetic liquid as coolant prevents lime deposits and corrosion Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

6. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 6 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics  Caking of material on the probe Minor deposits are removed during regular automatic retraction and cleaning with compressed air.  High maintenance costs Thanks to the high operating temperature and the effective method of cleaning our system can achieve periods of maintenance free operation up to three months The Problem and our Solution The problems with the gas analysis in cement rotary kilns can be minimized or eliminated by using our patented gas sampling system Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

7. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 7 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics FLK Gas Sampling System Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

8. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 8 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Gas Sampling probe  for gas temperatures up to 1400  C  gas sample temperature up to 200  C  lateral intake chamber to reduce entry of dust  self-cleaning of dust deposits during retraction and insertion  variable probe length to meet the customer requirements  high mechanical stability due to oval design Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

9. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 9 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Automatic Retraction unit  in case of faults the probe is retracted automatically from the kiln  redundant motorized retraction due to electrical and pneumatic motor  heavy duty and maintenance free mechanical design Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

10. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 10 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Dedusting Filter  electrically heated operation  operating temperature controlled by thermostat  maintenance free sinter metal filter  preheating of compressed air Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

11. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 11 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Purge unit  automatical cleaning of gas paths  adjustable cleaning cycles  minimum pressure recognition Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

12. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 12 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Heat exchanger  synthetic coolant  high boiling point  environmentally friendly  closed coolant circulation, pressure free operation  monitoring of temperature, flow and level  operating temperature adjustabel (130  C – 220  C)  fast and easy installation and commissioning Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

13. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 13 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Heat exchanger Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

14. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 14 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Control- and monitoring unit  Compact cabinet  with SIMATIC S7-300 or Allen Bradley SLC500  central power distribution  Function  controlling of purge cycles and gas sampling  monitoring of temperature, flow and level  automatical probe retraction in case of faults  easy to change parameter settings without programming expertise Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

15. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 15 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Gasflow and cooling circuit Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

16. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 16 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry Process Analytics Gas treatment and Analysis Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

17. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 17 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry  Up to 3 IR absorbable gas components plus oxygen  Easy-to-use menu driven operation  AUTOCAL with ambient air Up to 8 gas components in one analyser cabinet with the Multi-Component gas analyser ULTRAMAT23 Gas treatment and Analysis Process Analytics Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

18. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 18 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

19. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 19 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

20. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 20 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

21. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 21 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

22. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 22 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

23. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 23 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

24. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 24 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

25. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 25 A&D PI2 SE1 Siemens Process Analytics in the Cement Industry FLK Gas sampling system Process Analytics Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

26. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 26 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry FLK Gas sampling system Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

27. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 27 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry FLK Gas sampling system Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

28. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 28 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry FLK Gas sampling system Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

29. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 29 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry FLK Gas sampling system / Benefits  Synthetic heat transfer liquid instead of water  Gas sample temperature up to 200  C  no condensation-build up in the sampling probe  no lime deposits and corrosion  no freeze over of the coolant  high availability and less maintenance compared with water cooled systems  Short commissioning time  the system comprise just 6 components  components ready to connect  typical commissiong time: 3 to 5 days Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

30. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 30 A&D PI2 SE1 Economic performance analysis of typical Customer benefits Optimized burning process  1% excess of Oxygen means: 10 kcal of extra energy consumption per kilo of clinker  In the case of a kiln with a capacity of 3000 tons/day operating 300 days a year, this means: 9.000.000.000 kcal of extra energy consumption per annum or 1.097.560 kg of extra coal consumption assuming an energy content of 8200 kcal per kilo of coal Process Analytics Siemens Process Analytics in the Cement Industry Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

31. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 31 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Economic performance analysis of typical Customer benefits Optimized burning process With a coal price of $ 45 per ton this means:  1.097,560 tons of extra coal x $ 45 = $ 49.365 higher energy costs  This saving means that the payback period on the investment in FLK GAS is less than 2 years And remember too that this does not even take into account the savings that can be made on maintenance compared with water- cooled systems Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI

32. Bereichskennung oder Produktname Process Instrumentation and Analytics Januar, 2003 Folie 32 A&D PI2 SE1 Process Analytics Siemens Process Analytics in the Cement Industry Economic performance analysis of typical Customer benefits Optimized burning process Applications Kiln inlet FLK sampling system Gas flow Gas conditioning Installation Benefits ROI