SCKGas sampling unit for cement kiln and calciner gas exit

2 ABB | SCK

Reliable gas sampling system – for rough environmental conditions

In a cement plant, the gas analysis at the kiln gas exit is a real challenge for a supplier of gas analysis equipment due to the hostile prevailing conditions. ABB’s new SCK sampling system is designed for sampling of hot cement flue gas with a high dust load for gas analysis. Usage sites are the rotary cement kiln gas exit and the calciner gas exit in dry process rotary clinker kilns.

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The experience gained by 500 installationsThe new sampling system SCK plus the gas analysis system ACX are the successors of the ACK.

The development of the new SCK is based on ABB´s experi-ence gained from its predecessors, of which more than 500 systems have been supplied worldwide.

Easy installationThe SCK system will be delivered completely preassembled to the installation site. Fewer cables and mounting parts for the client reduce the risk of incorrect mounting. The installation time of the system is reduced significantly. The SCK system consists of the following three modules:

− Probe retractor with pneumatic motor and chain driven water-cooled probe

− Control unit with industrial controller and touch panel operation

− Cooling unit with speed-controlled heat exchanger and cooling water circulation pump

High developed technology – SCK advantages − Complete sampling system − Quick and easy system setup − Pneumatically driven probe retractor with dust cover

and automatic oven flap − Unique choice of two probes for optimal suitability

to your process − Automatic cyclic cleaning of probe and filter − Control unit with touch panel featuring comprehensive

operation, diagnosis and maintenance capabilities − Remote operation and diagnosis

Probe retractor

Cooling unit

Control unit

4 ABB | SCK

Robust retractor and probes – for safe sampling

Pneumatically driven retractor for probesThe retractor with its pneumatic chain drive carries the gas sampling probe in a double beam construction. It is used for inserting and retracting the probe to defined front and rear positions to scrape off possible material deposits or encrus-tations.

The integrated pneumatically driven oven flap closes the sampling opening after the probe is completely retracted, thus preventing hot and toxic gases to exhaust from the kiln and cause hazard to operators and machinery.

A complete top cover protects the moving parts from dust.Due to the design of the retractor, the tip of the probe is easy accessible for inspection and cleaning purposes at any time.

Your advantages– Pneumatically driven oven flap for your safety– One system with two probes options– Probes for extremely hard encrustations– Easier handling for inspections and cleaning

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Complete solutionThe SCK sampling system is preferably combined with ABB’s ACX gas analyzer system. The ACX gas analyzer system ensures effective monitoring of the primary and secondary combustion, validates the clinker quality, minimizes the fuel costs through optimized combustion control and supports a safe operation. The combination of SCK with systems of third-party manufacturers is also possible.

Water-cooled probesABB is the only supplier on the market that can offer two different water cooled probes for the kiln application:

Probe H – for extremely hard encrustationsProbe H is preferred where extremely hard encrustations are to be expected. The pneumatically driven plunger, which is welded on the filter tip, mechanically breaks the encrustations at the probe gas entry without interruption of the measure-ment.

Probe 60S – for normal encrustations Probe 60S is the choice for kilns where less hard encrusta-tions are to be expected. Different from other probes on the market, the tip of Probe 60S has a de-dusting effect, which reduces the dust entering into the sample.

6 ABB | SCK

All under control – user-friendly operation, diagnosis and maintenance

Predictive maintenance at your fingertips The graphical visualization of important signals like tempera-ture and flows allows the monitoring of trends. In addition the operator can freely set pre-alarm limits, meaning he will be automatically informed in advance before a signal reaches a critical value. This can also be shown remotely on any PC by Ethernet networks and is especially comfortable for service purposes.

All under control – no specialist required The industrial controller including touch panel operates the complete system. The program sequences are menu-driven and enables

− Diagnosis (water parameters, status) − Operation (automatic/manual, flap, probe cleaning, etc.) − Login levels (operators, technicians, etc.) − Messages lists (status signals) − Set-up page (times, limit parameters, etc.)

Remote access – made easy Moreover the control unit enables remote diagnosis via standard Ethernet connection. Data can also be saved on an USB-stick and transferred via e-mail to an ABB service center. The new industrial controller allows a plant technician to trace the program sequences step by step to support mainte-nance work. These features give additional comfort and lower the cost of ownership for the client.

Via Profibus connection, the operator has remote control of the SCK system, enabling retraction, insertion and back purging of the probe.

Periodically sampling and measurement at the kiln gas exit is possible according to the operators measurement needs.

The controller is completely menu driven for easy commis-sioning and configuration of cleaning cycles, limit values, periodical sampling according to the operators needs, without any complicated PLC programming.

Environmental awareness Due to the prevailing conditions a cooling of the sample probe is mandatory. ABB uses a closed water circuit for a safe and environmental friendly cooling. Analog sensors monitor water flow, temperature and pressure continuously. This gives the operator in the control room a complete control of the system conditions.

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The Added Value What you can expect from a market leader

Unique time and cost saving calibration concepts ABB has 30 years of unrivalled experience in producing gas-filled calibration cells, allowing calibration without test gas bottles for their Photometers. Single-point calibration with ambient air as the standard gas is also possible.

Unrivalled options for connectivity ABB’s gas analyzers and systems excel in Ethernet network abilities and Modbus or Profibus interfaces. This enables the analyzer data to be easily read, archived and visualized on a PC, PLC or process control system.

Assured quality through independent certification ABB provides international certificates for CEMS, hazardous area installations, metrological approvals, electrical safety and quality management.

Best choice of analyzers tailored to your needs ABB Analytical offers the broadest selection of measuring principles under one roof. All types of analyzers share a common operation to reduce the need for training and spare parts.

Certified support wherever you are Manufacturer certified service specialists with many years of experience and comprehensive know-how are ready to assist you in word and deed. ABB delivers analytical solutions to all industries since more than 70 years. Our engineering specia-lists are professional partners in finding the perfect matching solution for your measuring tasks in your application.

Long-term security in your investment Even after the end of production, ABB Analytical products are maintained for many years. A fully transparent and com-prehensive life cycle policy ensures long-term availability of spare parts and support.

Most powerful software solutions Full remote control and maintenance access to the system in-side a protected network. Integrated controllers allow tailored functionality to control the measuring chain from sampling to the gas outtake.

As one of the world’s leading engineering companies, we help our customers to use power efficiently, to increase industrial productivity and to lower environmental impact in a sustainable way. With the added values ABB Analytical helps to improve performance and reliability at work.

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Note:We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB.

Copyright© 2009 ABBAll rights reserved

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