This document discusses air leaks in a cement factory production process and the opportunities to save costs by closing vacuum and air leaks. The cement production process involves raw material crushing, grinding, drying in a preheater and kiln, cooling and storage. Air leaks in the preheater and kiln can lower temperatures and require more fuel to compensate. They also risk exceeding environmental regulations. The document recommends using a Fluke ii900 sonic industrial camera to easily and quickly detect air leaks without a production shutdown, saving time and maintaining output.

1. Not For Distribution
Cement Factory
Air Leaks & Energy/Cost Saving

2. Cement Factory Process
© Fluke Europe BV Company Confidential - Fluke 438 introduction 2
Raw material Crasher Mixing + other material
Grinding & dry
 fin powder
Preheater
Kiln/Oven
Cool down
and store
Add other
material
Converted
to cement
Storage packing

3. @Preheater
@Oven (Kiln)
3
Preheater
Kiln/Oven
Air Leaks cause:
- Less drying
- Lowering temperature
- Loss in energy
- Loss in Fuel
To compensate :
- Increase Fan speed
- More Fuel
Vacuum
is Critical
Done by Big Fans
Effected by
Opportunity to save Electricity + Fuel/Gas
By: closing possible vacuum leaks (- pressure)
Opportunity to save Electricity + Fuel/Gas
By: closing possible vacuum leaks (- pressure)

4. @Homogenizing
@Oven (Kiln)
@Cooling Down and Storage
4
a. Material Transferring in and out
b. Combustion air feeding O2 for fire
Air Leaks cause:
- Longer time for the process
- Less efficiency
- Loss in energy
- Time loss
Compressed
Compressed
Air
is Critical
Opportunity to save Electricity + Process Timing
By: closing possible air leaks that will increase Air compressor efficiency and live time
Opportunity to save Electricity + Process Timing
By: closing possible air leaks that will increase Air compressor efficiency and live time
Kiln/Oven Grinding & dry
 fin powder
Cool down
and store
To compensate :
- Increase air pressures
from compressors
Aeration & Filter dust
Air Leaks cause:
- Less efficiency
- Loss in energy
- Time loss
To compensate :
- Increase air pressures
from compressors
Transportation & Cooling
Air Leaks cause:
- Longer time for the process
- Less efficiency
- Loss in energy
- Time loss
To compensate :
- Increase air pressures
from compressors

5. @Transporting Material in all process
5
- Sealing air to protect the Coriolis mass
flow meters from coal dust damage.
- Harsh conditions (high temperatures,
moisture, dust tear and wear).
- Smooth material transporting
- Coal dust damage
- Deformation of the installation
- Production Problems
- Leaks
Compressed Air
is Critical
Opportunity to save Time,
Maintain production
By: continually looking for
air leaks and fix them
Opportunity to save Time,
Maintain production
By: continually looking for
air leaks and fix them
Cause

6. @CEMS
Continuous Emission Monitoring System
6
- Reducing fuel consumption and consequently the emissions coming from leaks in the
Preheater and Kiln section result into pumping more to reach needed temperature.
- Exceed the Environmental Regulations which put limits to the release of gases in the
atmosphere which will cause pollutions which might cost a penalty fees.
Monitoring Leaks
will contributor on

7. Challenges & Solution
Finding Leaks
Challenges:
Current technology needs:
A- Expert operator
B- Quite place (shutdown)
C- Other task need to be done during Shutdown!
D- Time consuming
E- Not easy to do inspection in harsh environment
Leaks found at:
Leaks found at:
Flange connections - Isolated
pipes - Vacuum lines - Branch
valves - Coolers - Filtration -
Valve diaphragms - Pneumatic
actuators - Bag filling…
Solution:
Fluke ii900 (Sonic Industrial Camera)
A- Easy to use – any technician can use it
B- No need for Shutdown (works in noise places)
C- Saves time due to fast scanning of large
inspection areas
D- Can see leaks from a great distance

8. Free Demo on-Site or online is Available
Contact:
Hassan Bahrani
Fluke Area Manager
Hassan.Bahrani@fluke.com
0544723330