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Reduction in maintenance costs and process stability thanks to reliable raw cement mass flow measurement
Construction materials industry | MaxxFlow HTC
Customer: Cement Company (Switzerland)
Material: raw meal
Throughput: 250 t/h
Conveying device: air slide
Installation location: Free fall after air slide
What measuring process was used previously: impact weigher
Function: Raw cement mass flow measurement to optimize the cement milling process

APPLICATION

A Cement Company located in Switzerland was facing a problem in measuring the Raw Cement throughput, which was around 250 tons per hour. The customer had previously installed an Impact weight meter with mechanical parts, but it required extensive calibration and was not providing accurate and consistent measurements. Additionally, the headroom available for installation was only 300 mm, making it even more challenging to find a measuring device that could fit in this space and handle such a large volume of cement. To overcome this challenge, the company required a more reliable and accurate measuring solution that could fit within the limited space available, which would enable them to better monitor and manage their production processes.

SOLUTION

The customer had previously used an Impact weight meter, but it required extensive calibration and was not delivering the desired results. Moreover, the limited headroom of only 300 mm made it difficult to find a suitable measuring device to convey this amount of cement.

The solution was to replace the Impact weight meter with the MaxxFlow HTC sensor, which is specifically designed for the flow measurement of dry bulk solids during high-volume throughput. The MaxxFlow HTC is capable of delivering accurate and consistent measurements without the need for mechanical parts, making it a reliable and compact device. The installation of the MaxxFlow HTC took place independently of the direction of the line and was carried out after mechanical conveyor elements such as rotary feeders and screw conveyors.

The ENVEA engineering team analyzed the mass flow, material density, and available dimensions to determine the appropriate sensor installation. The customer used the MaxxFlow DN200 sensor and reduced the inlet cross section down to 200 mm using a reduction chute, which did not interfere with the mass flow and did not create further blockages. The customer and the ENVEA engineering team agreed on the new design, which would not cause any failures in their process or downtime, leading to a successful project execution.

CUSTOMER BENEFITS

  • Stable calibration and measurement, measurement without mechanical parts
  • Drastic reduction in Maintenance Costs
  • Process consistency thanks to stable and reliable measurement

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