Ciment Québec Optimizes Tertiary Air Performance - Case Study
Ensuring controlled air split between tire combustion and kiln inlet for stable operation without gas overfeeding or process imbalance
THE TASK
Ciment Quebec required a robust and reliable solution for measuring and balancing tertiary air flows within its pyro system. The application was characterized by harsh operating conditions, including high clinker concentrations, temperatures up to 1200°C (-2200 °F), and continuous 24/7 production. Reliable insight into air-fuel-distribution between AF combustion and kiln air inlet was essential to maintain balanced combustion conditions, optimize thermal substitution rate performance, and ensure efficient and consistent rotary kiln operation.
THE SOLUTION
PROMECON implemented a digital TA flow measurement system installed in a rising section of the TAD, specifically selected to ensure representative flow conditions. The system provides continuous realtime measurement of volumetric flow (mVs) and gas velocity (m/s), enabling direct operator interaction and control via damper adjustments for optimized alternative fuel combustion air balancing and stable kiln operation.
The non-intrusive, infrared measurement principle is designed for harsh environments, delivering drift-free and zero maintenance performance throughout the entire campaign. Only a permanent purge air supply is required, protecting the sensor while maintaining measurement accuracy. This robust setup enables long-term operation without recalibration or mechanical intervention.
THE BENEFITS
- Real-time visibility of actual tertiary airflow
- Better process evaluation enables optimal control of HOTDISC® combustion conditions
- Improved air distribution between kiln and alternative fuel combustion reactor
- Improved operational flexibility under variable conditions, especially by multi-fuel operation
- Lesser calciner shutdowns and incomplete combustion
THE RESULT
- Increased Alternative Fuels Rate
- Up to 15% improved specific energy consumption (GJ/t clinker) in combination with a new generation of multi-fuel burner technology and smart expert system
- More stable kiln and HOTDISC* energy balance
- Clear identification of damper aging effects on flow behavior