Efficiency and safety of cement production has been limited for decades by ineffective measurement technologies or manual processes. Non-contacting radar level technologies are changing the dynamic and revealing new ways for plant operators to keep tabs on crucial parameters that can help streamline operations, reduce costs and protect personnel.
Challenges in Cement Production Storage Tanks
One of the obvious limitations of most measurement approaches is how level is typically measured in storage tanks where raw materials such as sand, limestone, or clay are furnaced and heated. The processing of these materials generates harsh conditions in the tanks, such as heavy dust and high temperatures, which makes accurate level measurement using traditional methods challenging in several ways.
- Inconsistent measurements. The dusty and harsh conditions inside storage tanks can affect the reliability of level measurements and increase the need for reactive maintenance. These tasks are often disruptive and can require expensive shutdowns, decreasing throughput.
- Personnel safety. The age-old practice of manually performing visual checks in tanks where product is stored under extreme conditions has always posed clear dangers to personnel—and it’s expensive.
- Lack of real-time data. The unreliability of devices or the absence of accurate level measurement technology has restricted the information available for making informed decisions. The poor visibility of operations hinders effective planning, which can cause out-of-stock situations, unplanned downtime and high operational costs.
Taking a Modern Approach
To get a feel for how modern non-contacting radar solutions can mitigate these challenges, consider how Holcim Group improved measurement reliability and reduced manual checks of its sand storage areas at a cement plant in Poland. Holcim used a non-contacting radar level indicator from Emerson to streamline operations by providing real-time data to plant operators and increased personnel safety by reducing the need for manual rounds.
Hot sand stored and furnaced in storage tanks at the Holcim Plant was difficult to measure using traditional methods which increased costs and introduced safety hazards.
Like Holcim, other cement facilities can improve efficiency by integrating non-contacting radar level sensors that utilize powerful technologies for robust, reliable level measurement across all tank sizes. With the ability to accurately track the level of materials in their storage tanks and reduce the total cost of operational ownership, cement plants can overcome each of the challenges outlined above, and gain key benefits, including:
- Consistent, reliable level measurement. Because non-contacting radar level indicators never touch the media in your tanks, the devices require very little maintenance, are immune to dust and temperature variations, and maintain very high levels of accuracy throughout their lifespan—which is considerable.
- Enhanced safety and reduced burden on operators. By sharply reducing the need for dangerous and costly manual checks, plant staff can avoid reactive actions and respond more effectively to emergency situations—and spend more time optimizing operations.
- Access to real-time data and insights. Non-contacting radar sensors improve visibility by delivering level measurement data in real time, bringing operators a complete and detailed view of their inventories so they can make faster and more informed decisions that translate to better operational plans.
How Emerson Can Help
Emerson’s Rosemount Non-Contacting Level Sensors are robust and easy-to-use which enables cement plant operators to confidently modernize their measurement process with minimal disruption. Using an intuitive software interface, operators are guided through installation, commissioning, proof-testing and maintenance.
When imbued with optional predictive maintenance features, the devices help operators detect issues before they lead to failures, saving costs and reducing risk to personnel and equipment. Once they are armed with consistent, automated measurement, plant operators can put data into action to facilitate better operational planning and gain a comprehensive overview of their inventories.
Holcim installed a Rosemount 5408 Non-Contacting Radar Level Indicator on top of a hot sand tank which continuously provides accurate, real-time level measurements.
Additionally, Rosemount Non-Contacting Radar Transmitters feature Smart Echo Supervision™ which reduces the sensitivity to obstructions inside the tank and ensures that level measurements are reliably and accurately reported.
If you would like to learn more about how the Rosemount 5408 Level Transmitter and our entire line of non-contacting radar solutions can help reduce operational costs, enhance personnel safety, and optimize inventory management at your cement plant, click on the links below.
