Types of Sensors Used in the Cement Industry - ClipOn

The cement industry is one of the largest industries in the world. With the current shift towards digitalisation, it is no surprise that sensing technology is becoming increasingly important in cement production. New sensors are being developed to monitor, control, and optimise manufacturing processes and provide real-time data for improved decision-making.

There are five main types of sensors used in cement production: temperature sensors, level sensors, vibration sensors, displacement sensors, and nanomodified smart cement-based sensors. Temperature sensors are used to measure the temperature of the material during the manufacturing process. Level sensors are used to measure levels of the material to control the process. Vibration sensors monitor the rolling displacement of slow-turning shafts and other machinery. Displacement sensors measure the distance between two points on a machine, allowing for precise movement control. Finally, nanomodified smart cement-based sensors are emerging self-sensing technologies for structural health monitoring that measure strain and stress on concrete structures. These sensors provide invaluable data for monitoring and optimising the production process and feedback for better decision-making. They can also be connected to the internet, allowing real-time data monitoring across entire fleets of trucks. This data can be used to improve efficiency and reduce costs for cement production.

Temperature Sensors: New sensor technologies are revolutionising the cement industry by providing reliable and accurate temperature readings in extreme environments. Manufacturers can improve production efficiency and upgrade their processes by measuring and monitoring the temperature inside a curing chamber. Thermocouples, temperature sensors, thermistors, and RTDs measure the temperature within cement plants and kilns. These devices are designed to withstand high temperatures and concentrations of clinker dust, providing accurate readings even in harsh conditions. Companies such as Peak, EI Sensor Technologies, and Process Sensors Corp are leading the way in advanced temperature measurement devices, offering high-quality solutions that are both affordable and reliable. Companies can also access sensors, cameras and accessories from Symaro for optimal control of the entire HVAC system. With these new technologies, manufacturers in the cement industry have access to more reliable temperature readings and improved production efficiency.

Pressure Sensors: The use of new sensor technologies in the cement industry is revolutionising the way the industry produces cement. Pressure sensors are one of the most important elements in modern cement manufacturing, as they provide accurate readings of pressure and help to ensure that the cement meets quality standards. Pressure sensors can measure the cement mix’s pressure, helping to identify any inconsistencies in the product. They can also monitor the production process, allowing for greater control over the entire process.

In addition to providing accurate readings, pressure sensors allow cement plants to maximise efficiency and reduce energy costs. For example, they can detect high-pressure areas in the mix and adjust the mix accordingly, resulting in a more consistent and reliable product. Pressure sensors are also invaluable in monitoring the temperature of the mix, ensuring that it does not exceed certain thresholds. As a result, the quality of cement produced can be improved significantly.

American Sensor Technologies (AST) is one of the leading pressure sensor manufacturers in the world, with a full line of products designed for any industry. AST’s pressure-sensing elements are machined from stainless steel and feature advanced digital signal processing technology. This allows them to detect even small changes in pressure and respond quickly, ensuring accuracy and reliability. AST’s pressure sensors offer increased accuracy and repeatability compared to traditional devices, making them ideal for use in the cement industry.

Overall, the use of new sensor technologies in the cement industry is helping to revolution

Level and Flow Sensors: New sensor technologies are becoming increasingly important in the cement industry. These sensors measure and monitor the level and flow of materials used in the production process. Level sensors help to accurately track the amount of material present in a given area, while flow sensors measure and monitor the speed and direction of material flow.

Thermal flow sensors are the cement industry’s most widely used type of flow sensor, as they provide accurate readings even under extreme temperatures. They can be used to measure both liquid and gas flows. Mechanical or mechatronic devices such as float switches can also sense flow. Other levels and flow sensor types include magnetic-inductive flow meters, differential-pressure sensing devices, and ultrasonic sensors.

Innovation in this field has led to the developing of new technologies that make it easier to run processes in the cement industry. For example, ABB’s next-generation probe, the ProKiln GAC400, offers precise flow control with its highly reliable level measurement system. Aplus Finetek Sensor Inc. has also developed improved technologies from traditional types to high-end types. Overall, level and flow sensors are essential for efficient and safe processes in the cement industry. By utilising the latest sensor technologies, companies can ensure that their production processes run smoothly and efficiently.

Vibration and Acoustic Sensors: Vibration and acoustic sensors are becoming increasingly important in the cement industry due to their ability to detect and analyse various aspects of the production process. New sensor technologies are allowing manufacturers to streamline operations and improve quality control. Vibration sensors detect any changes in the vibration of machinery, which can indicate a malfunction or other issue. They can also be used to measure the efficiency of machines and provide feedback for maintenance and calibration purposes. Acoustic sensors measure sound waves generated by machines and other equipment, allowing manufacturers to identify any acoustical issues that may need to be addressed. These sensors can detect high noise levels and any changes in sound frequency or intensity.

These sensors are becoming more commonplace in the cement industry as manufacturers look for ways to improve efficiency and safety without sacrificing quality. With advanced sensor technology, manufacturers can monitor their equipment more closely and quickly identify any issues before they become major problems. As a result, production costs are reduced, and quality is improved.

Gas and Air Quality Monitors: The cement industry has always been a major contributor to air pollution, with high dust and emissions released into the atmosphere. The industry has begun investing in new sensor technologies to manage these emissions better and ensure workers’ and nearby residents’ health and safety. These technologies allow for real-time monitoring of gases and air quality, providing early warnings of potential risks. The most common sensors used in the cement industry are those that measure pollutants such as carbon monoxide (CO), nitrogen oxides (NOx), sulfur dioxide (SO2) and ozone (O3). This data is relayed in real-time to local authorities or companies, allowing quick decisions. For example, if a certain pollutant threshold is reached, production can be shut down or reduced to reduce the risk of exposure.

Another application of new sensor technology in the cement industry is flow control. Companies like Senko have developed low-cost, portable air quality sensors that can monitor cement plants’ air/gas/water/fluid flow. This technology can detect any blockages or other issues that could lead to explosions or the self-ignition of coal. It also provides vital information on pressure levels and temperature, helping operators ensure optimal performance while keeping everyone safe. Finally, companies like OpenSensors have created solutions specifically designed for monitoring air quality in offices. By installing these sensors, companies can ensure that their work environment is safe